Terry Towel

A terry towel is a textile product which is made with pile loops on one or both sides covering the entire ground surface or forming pile strips, pile checks, or other pile patterns (with hemming end or with firm selvedge). Turkish Towelling fabrics structures form a class of warp pile termed terry pile in which certain warp threads form loops or curls on the face of the cloth.  We may use one weft and two series of warp threads placed on two warp beams are necessary for the production of this cloth. Cashmere Towels are made of Superior Ring-Spun Quality Yarn. They are soft and luxurious and will provide a sense of comfort to your valued guests.  Cashmere Towels are the best choice you will make by balancing luxury and cost. Fibre Raw materials used for terry towels: Cotton, Bamboo, Model, Lyocell, Flax, Synthetics microfibers (polyester, nylon), Cashmere.

Types of Bath Towels

Towel type Size Best Uses
Bath Towel From 27″ x 52″ to 30″ x 58″ Small bathrooms
Kids’ bathrooms
Guest bathrooms
Bath Sheet From 35″ x 60″ to 40″ x 70″ Master bathrooms
Large bathrooms
Hand Towel From 16″ x 28″ to 18″ x 30″ Any bathroom
Powder room
Finger Towel 11″ x 18″ Small bathroom
Powder room
Washcloth About 13″ x 13″ Showers and bathtubs

Classification of Terry Towels:

Table Classification of Terry Towels according to Weight, Production Style, Finishing, Weft Count Per Pile Loop and Pile Presence on Fabric Surfaces

Weight Production Finishing Weft Pick Count Per Pile Loop Pile Presence on Fabric Surfaces
Very heavy (>550 g/m2) Woven Velour Towel Two-pick Terry One side pile
Heavy (450-550 g/m2) Weft Knitted Printed Towel Three-pick Terry Both side pile
Medium (350-450 g/m2) Warp Knitted Towel with Embroidery Four-pick Terry
Light (250-350 g/m2) Towel with appliques Five-pick Terry
Six-pick Terry
Seven (or more)-pick Terry

In velour towels, pile loops on one side of the fabric are sheared in order to give a smooth velvet appearance, good drape and improve upon absorbency. A towel with appliqués is embellished with additional pieces of decorative fabric in a motif that is stitched onto the towel. Two-pick terry towels that were woven for bathrobe end-use have lost their importance today due to the instability of the loops.

Five or more pick terry towels are rarely produced because they need to be beaten for each pile twice. The most common towels woven are three pick terry towels and are universally accepted. As one-sided pile toweling has low water-absorbing and visibility of more defects like bareness, irregularity, etc.

The Manufacturing Process of Terry Towels

Spinning

This is the process where selected fibers are converted to yarns of desired counts needed for towels. Some integrated textile toweling mills produce their own yarns for towels. They purchase bales of cotton of a specific grade as per their working plan.

  • Mixing of fibers are formulated as per the required plan and is subjected to required atmospheric conditions before they are passed through the blow room line. Here strictly mill mixing plan is being followed. According to the mix plan selection of machines to process and their machine settings are made before mixing is allowed to pass through the blow room line.

  • Once planned results in the blow room process are accomplished then these fibers are passed directly through chute feeding to well-set carding machines and fibers are converted into slivers.

  • These carding slivers are tested for various technological parameters before they are passed to the next process Drawing frames. These draw frames are set as per working plan and slivers are passed through for effective blending and parallelization of fibers. Draw frame slivers are tested for parameters and if passed they are further processed. Draw frame slivers may be semi-combed then again passed through draw frames before they are fed to roving frames (Speed frame).

  • Slivers are converted to rovings of specified hank as per the spinning plan. Thereafter these roving bobbins are fed to ring frames well set with technological parameters as per spinning plan where they are converted to particular yarn counts to be used for terry towels.

  • These ring bobbins are fed to automatic winding machines where the yarn is converted to packages. These winding machines are also ser for different settings required as per the spinning plan.

  • Whenever double yarns are needed for weaving terry towels the single yarns are processed on TFO machines to convert them to double yarns with defined twist factor and direction of the twist as required for towels.

Preparation of spinning plan is very critical and needs a lot of knowledge and understanding of spinning technology. The application of this spinning plan determines yarn parameters and yarn quality and hence needs close supervision from process control and quality control laboratory.

Weaving

Yarn packages are assembled on warping creel as per construction plan, required tensions are set on each yarn package and are processed on sectional or direct warping machines depending on single/double yarns are used.

All machine settings, machine speed is set as per instruction sheets of weaving plan. All warping sets made from single yarns are processed on sizing machines where a starch coating is applied on individual threads to make it weave able on weaving machines. Double yarns sets may or may not be passed through sizing machines. Single sized beams and double-sized or unsized beams are taken to drawing in department and beams are drawn as per drawing in weaving plan to make them ready to load on weaving machines.

Loading of beams is a high skill job that is to be carried out under the close supervision of weaving staff.

Before machines are loaded on weaving machines, machines are to be well set, speeds adjusted as per an article by experienced, skilled and qualified weaving staff. The use of machine setting sheets as per the weaving set plan is essential and important before the machine is set for production. Process control staff and weaving senior staff have to monitor the initial production of a few towels and inspect the machine and off the machine the various parameters of the towel and should exactly match as per weaving plan. Once passed the machine is allowed to go into production.

Mechanism of terry weave in terry fabric manufacturing, two sheets of warp threads run simultaneously, of which, one is kept under normal tension and other is kept under loose tension. The threads of normal-tension warp sheet are for ground and threads of loose tension warp sheet are for the pile.

Bleaching

These selected rolls are transported by using recommended trolleys to bleach section and are bleached in the J-Box machine which is a continuous bleaching machine. The fabric is treated with bleaching recipes such as hydrogen peroxide, caustic defoamers, and other ingredients.

Reaction time and machine speed have to be set as per process plan prepared after considering all activity factors. After the roll is bleached it is sent to washing machines and washed thoroughly so that no trace of chemicals remains on the fabric. Then these rolls are dried and sent to Dyehouse. All procedural requirements are followed so that the rolls can be identified at any stage during processing and in storage.

Dyeing

As per requirement order from dye house, bleached rolls are transported to dye house for dying operations for various colours as per dye house planning sheets. Dried uncut rolls are taken to Dying machines for dying with vat colour using vat dye receipt. This has proven over time to provide colourfast towelling after extensive residential laundering.

It is sent to washing machines and washed thoroughly so that no trace of chemicals and loose dye particles remain on the fabric. Then these rolls are dried on an air-drying machine and sent to folding cutting/folding and packaging department. All procedural requirements are followed so that the rolls can be identified at any stage to avoid mix-ups during processing and in final storage.

Cutting, folding, and packaging

As per final inspection plan, rolls are transported with special care to finish folding department.

Instruction techniques to follow are for visual inspection

  • Step 1: is to open these rolls and are cut as per instruction sheets
  • Step 2: is to stitch / ham towels
  • Step 3: Each towel stitched is inspected by a quality inspector attached to a respective table. He has to ensure defect-free towel on both sides, the label for passing and sent to the final inspection table. The rejected towels are to be kept separately for operational departmental inspection
  • Step 4: Final inspection by a senior inspector passed, labeled and sent for final packaging and dispatching. Rejected towels are kept separately.

Quality Control

Quality assurance department plays an important role to monitor, check, and control each manufacturing activities and operations from receiving all raw material to the final dispatch of products. This is controlled through close supervision and active participation of on-line process control and off-line quality control laboratory. Most common defects found in terry towels are…

Objectional odours, Holes (two or more broken ends), abrasion mark, Bow, Skew, crease, oil stains, dye stains, miss pick, double picks, sharp pressmark, fibre contamination, dye/bleach shade variations.

All Towels manufacturing mills need to have a strong quality assurance department which is capable to coordinate with the production line and assist them to provide vital quality productivity information continuously.

All incoming inputs bought for the manufacturing process are thoroughly examined for their quality parameters as laid down by production plan before they are used during manufacturing operations.

Caring for your Towels

  • Wash towels at between 40-60°C
  • Wash with similar colors or use a color catcher
  • Tumble dry towels to keep them soft and fluffy
  • Use fabric conditioners sparingly and not in every wash as they decrease absorbency
  • Wash separately from garments with zips or trims to avoid snagging
  • Shake towels before washing –this opens up the fibers slightly to allow the detergent to sink inside.

GSM

GSM is the short form for grams per square meter. All fabrics including towels have a measurement in weight, and the standard measurement is measured in grams per square meters. This number refers to the density of the towel. High-quality Turkish cotton towels are generally heavier and are more absorbent.

Towels can vary anywhere between 300 GSM and 900 GSM. The lower the number, the lighter and thinner the towel. For instance:

300-400 GSM – In this weight category the towels are lighter and thinner. Depending on its use, a lower GSM for the towels is manufactured for a gym towel or a kitchen towel. A lightweight, shared beach towel might be around 350 GSM. Medium weight is 400-600 GSM. This weight is great for beach towels, bath towels, guest towels and so forth. Each consecutive gram weight –400, 500, 600– gets a little heavier, and a little more absorbent.

600-900 GSM – This is a premium, luxury weight. The towel will be denser, heavier, more absorbent. It will probably take a little longer to dry.

Packaging & Load-Ability

Packing Bags                  : 25 kg & 50 Kg PP Bags
Minimum Order Quantity : 1 x 20ft Container
Load-Ability                     : 24 MT in 20 ft Container
Supply Capacity              : 5 to 10 containers/months.