Textiles - Product Overview

Yarns
Yarns are strands of fibres which have been spun and are used for the weaving of fabrics. They can be produced from natural fibres, chemical fibres or a combination of both. Thus, yarns are the basic raw materials in the production chain for the manufacturing of textile products. Each type of yarn has its own qualities and they are often blended to take advantage of the best
properties of each material. As yarns are the basic raw materials used for weaving, the composition of yarns used determines the basic texture and characteristics of the fabrics to be produced.

Cotton Yarns
Cotton yarns are made from 100% cotton. It is one of the most widely used materials in the textile and garment industry due to its various favourable properties:-
absorbency : cotton provides high level of comfort as it can draw moisture from surrounding air creating a softer texture
heat retaining : cotton fibres contain air pockets to form an insulating layer
heat resistance : cotton can withstand heat of up to 110 degree celsius and is thus durable, and dyeing and washing friendly
alkali resistance : cotton has a relatively high resistance against alkali allowing cotton fabrics to undergo various dyeing, printing and postweaving treatments necessary for the making of different cotton based products
harmless to human body : cotton is totally natural and is harmless to human body
Combed cotton yarns are extra-soft cotton yarns and are regarded as one of the cleanest and most uniform cotton yarns. To produce combed cotton yarns, cotton is subject to a carding and combing process by which, short fibres and unwanted materials are thoroughly removed, leaving clean and lustrous fibres for spinning. The result produces high-quality yarns with excellent strength and softness. Cotton yarns are used to produce an array of textile materials, such as apparel, towels, pillow cases and blankets.

Chemical Yarns
Chemical fibres can be categorised according to their source of raw materials, namely man-made or synthetic sources

Man-made fibres are derived from cellulose materials from natural sources, such as wood, bamboo, aloe vera or soya bean, and are subjected to chemical and mechanical processing. Examples of man-made fibres include viscose , rayon and acetate . Synthetic fibres are derived
from petrochemical products; examples of synthetic fibres include nylon , polyester , spandex
and acrylic . Unlike natural fibres, the properties, composition and structure of chemical fibres are usually customised through various artificial processes to achieve desired characteristics, such as tensile strength, elasticity and absorbency.

Chemical fibres are believed to be more durable and easier to maintain. In particular, synthetic fibres, derived from non-cellulose materials, could be produced in bulk with relatively ease as they do not require an extensive area for cultivation and processing. The applications of different types of chemical fibres vary depending on their respective characteristics. For example, polyester, being known for its durability, and spandex, being known for its elasticity, are widely used in sports apparel. Due to its versatility, chemical fibres are often added with new elements to achieve specific functions, such as antibacterial function, to become functional fibres. Chemical fibres are widely used in sports apparel, functional outfits, such as bullet-proof and heat-resistant clothing, and umbrellas.

Loom-state Fabrics
Loom-state fabrics are plain fabrics, woven from yarns, without any further treatment that alters or enhances the properties of the fabrics woven. Thus, the production of loom-state fabrics is considered as the second step following yarn production in the production chain for textile products. Loom-state fabrics are usually subjected to further processing, such as chemical treatment, dyeing, printing and finishing, before being transformed into consumer products.

The Manufacturing Process Above

Manufacturing of Yarns
Inspection of raw materials
Upon receipt of raw materials, mainly cotton, the quality testing centre will examine the quality of the cotton, including its colour, tensile strength, fibre length, purity and texture. The cotton will then be categorized for the production of different grades of yarns according to orders received.

Carding and combining
Cotton from several bales is mixed and blended together to provide a uniform blend of fibre properties.The blended cotton is then transferred to cleaning and combing machines which separate and align the fibres into a thin web while removing majority of trash and unwanted materials. Upon completing the quality test, the web of cotton fibres will then be combined to form a rope-like form called “sliver” which will then be subject to further combing.

Combing
Combing is an extensive cleaning process necessary for the production of combed yarns. The comber is a complicated machine composed of grooved feed rolls and a cylinder that is partially covered with needles to comb out short fibres and foreign materials thoroughly.

Spinning
During the spinning process, combed cotton fibres are combined, drawn, blended, twisted, stretched repeatedly until they are spun into yarns with the desired thickness or “count”. The yarns can be stretched several times their original length and twisted many times per inch. The continuous stretching and twisting allows the yarns to achieve its essential textile properties, such as tensile strength, resilience and softness.

Winding and inspection
This stage involves winding yarns into reels through the use of automated winding machines. When the desired length of a cotton yarn is reached, the cotton yarn will be cut automatically.
Packaging and delivery of yarns
Upon satisfactory visual inspection, the finished products will be packaged according to orders for delivery.

Manufacturing of Fabrics
Warp formation
The yarns will be placed on a beam in a parallel direction to form the warp.

Sizing
To facilitate the interlacing of the warp and weft during the weaving process, a chemical solution, known as size, will be applied on the warp yarns to increase its strength and smoothness.

Shedding
Strands of warp yarns will be placed through a combination of eye holes attached on the frame of a loom, known as the heddle frame. The arrangement of these yarns through the heddle frame determines the weave patterns, dimension and thickness of the finished fabrics.

Weaving
During the weaving process, selected warp yarns will be lifted, according to the pattern directed by the heddle frame, to form a space through which the weft yarns can be inserted. The interlacing of the warp and weft yarns weaves fabrics according to a specified pattern.

Inspection
The loom-state fabrics will be visually inspected by our quality assurance staff before sending for packaging. Minor defects will be identified and rectified accordingly.

Packaging and delivery of fabrics
Upon satisfactory inspection, finished products will be packed and delivered to customers.