How sheets are made?

The Production Process

1. Material Preparation

• Fiber selection and preparation：First of all, we need to choose the right fiber materials depend on the products, such as Bamboo, Lyocell, Cotton, Linen, Microfiber/Polyester and so on. These fabrics have its own features, such as Bamboo has a silk feeling and high thermal conductivity, while polyester fiber is durable and easy to dry.
• Quality Control: The quality of the materials is strictly inspected to ensure they meet the required standards.
• Blended or pure：Depending on our client's needs, client can choose to blend different types of fibers for a particular performance.
• Yarn Spinning: The raw fibers are spun into yarn. The strength, uniformity, and twist of the yarn are carefully controlled.

2. Weaving

• Beam-warping：Warping is winding a certain number of warp threads parallel to the warp shaft or knitting shaft according to the specified length and width. This process ensures uniform tension, no damage to the warp, uniform alignment, and uniform winding density for subsequent sizing, threading operations, and weaving. Warping is an important link in textile production, and its quality directly affects the quality and performance of the final fabric.

• Fabric Weaving: The yarn is woven into fabric on a loom. The density, specifications, and types of weaving of the fabric are closely monitored.

3. Preconditioning

• Pre-Shrinking: The fabric is pre-shrunk to prevent shrinkage during subsequent processing and use.
• Bleanching: Chemicals or other methods are used to remove impurities from the fabric. To improve the whiteness and brightness of the fabric.

4. Printing and Dyeing

• Design pattern：According to the market demand and consumer preferences, designs the patterns and sizes of the bed sheets.

   

• Printing and Dyeing: If a specific pattern or color of bed sheet is required, it can be printed and printed after weaving. The printing and dyeing process can be selected according to the design needs.

5. After Finishing

• Additional Treatments: The fabric undergoes additional treatments such as softening and wrinkle-resistance.
• Washing: The pH value of bedding is mainly affected by the control of the post-treatment washing process. ‌These operations are usually carried out under alkaline conditions in the pre-finishing treatment and dyeing process. To bring the pH level up to standard, ‌ it must be washed to reduce it. ‌ If the washing process is not strictly controlled or the washing time is artificially shortened, the ‌pH value is difficult to meet the standard. Therefore, ‌the bedding manufacturers must ensure that the washing process is properly executed. To enhance the functionality and comfort of the fabric.

6. Cutting and Sewing

• Cutting: Use a cutter to cut the fabric to the desired sheet shape and size. In order to reduce manufacturing costs and improve manufacturing efficiency, it is often necessary to cut several layers of cloth at a time, so how to cut the cloth needs to be planned first.

• Sewing: Use a sewing machine or sew the edges of the cut sheet by hand to ensure smoothness and durability. This process also prevents pilling from appearing in the fabric during use.

• Quilting: Quilting is a textile technique ‌that originated in France; it is a thick and bulky embroidery, ‌usually filled with silk, ‌cotton, ‌microfiber/polyester, fur, or ostrich wool.

• Fibre Filling: Polyester, after special processing and post-treatment, with a certain linear density, cut length, and curl degree, can be used as cotton clothing and ski coat wool and as pillow, cushion, bedding, sleeping bags, toys, and other filling fibers. The following image shows the machine and filling process for filling this treated fiber into a pillow.

• Add Details: If desired, decorative or functional elements such as lace, buttons, zippers can be added to the sheet.

7. Quality Inspection and Packaging

• Comfort Ironing：Use an iron to iron the sheets to remove wrinkles and uneven parts.
• Broken Needle Inspection : This step includes an inspection of the finished bedding, and an inspection through a probe machine that can detect accidental broken needles in the bedding. The picture below shows the needle inspection machine, which will issue a warning if there is a broken needle in the product.

• Quality inspection: Linen is inspected before delivery to ensure compliance with relevant standards and requirements. The content of quality inspection may include dimensions, colors, sewing quality, washing performance, etc.
• Packaging: The sheets are folded, packaged, and prepared for shipment.

8. Transportation and Sales

• Transportation: The bed sheets are transported to sales channels.
• Sales & Marketing: The products are marketed and sold to consumers.

Conclusion

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