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 is formulated as per the required plan and is subjected to required atmospheric conditions before they are passed through the blow room line. Here strict 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 the 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 and 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 the 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 set 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 a 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.

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

All machine settings and machine speed is set as per the instruction sheets of the 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 them 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 the department and beams are drawn as per the drawing in the 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, and 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 should exactly match the 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 the other is kept under loose tension. The threads of the normal-tension warp sheets are for the ground and the threads of loose tension warp sheets are for the pile.

These selected rolls are transported by using recommended trolleys to the 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 the 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.

As per the requirement order from the dye house, bleached rolls are transported to the dye house for dying operations for various colours as per the 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.

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.