Heavy rains and unusually high temperatures are what make the cotton we source uncommonly durable. By harnessing this high tensile strength, we’re able to pull, stretch and twist each fiber to its very limits, so that we can make the most comfortable and reliable home textile products on the market.Continue to Pre-weaving →
Once spun onto a cone, the yarn must be treated to protect against the mechanical stress of the weaving machines. This is done by applying a sizing agent that coats and strengthens the yarn. We make it a point to only use all natural and environmentally safe sizing agents in our factory, to make sure our manufacturing process as ecologically friendly as possible.
Once the sizing agent is applied, the yarn is placed on the loom in parallel rows of yarn called the warp. Since the loom stretches the warp yarn at a consistent high tension during this process, the warp yarn must be very strong to withstand the rigors of the weaving process. Any yarn that breaks during the warping phase is immediately identified by our tension sensors and replaced.
Dobby weaving is the most basic form of weaving. Through this process the weft yarn, also known as the filling yarn, is interlaced with the warp yarn through a simple over-under technique. This is accomplished by the warp threads being moved up and down to create a space for the weft to pass through in a shuttle. This process is typically used to create a product with a single color, or a basic pattern.
Jacquard Weaving is defined by the ability to control each warp thread on a per-row basis. The advantage of this approach is that it allows for fabrics to be produced with far more intricate patterns than can be achieved with plain weaving, since rows don’t have to be treated uniformly.
This form of weaving is unique because it uses two systems of warps: pile warps and ground warps. Both sets of yarn are placed on the loom, but on two different section beams and at different lengths and tensions; the ground warp is tightly tensioned and shorter while the pile warp is lightly tensioned and longer. The result of having these two types of warps is that when the weft passes through, it creates basically two types of weaves: a tight, firm mesh with the ground warp, and a loose, loop-like weave with the pile warp. Occasionally, the loops of one side of a terry product are shorn, giving that side a soft, velour-effect.
This method of dyeing takes the fabric directly from the loom, and is used primarily for products that are intended to be a solid color. Through this process, a continuous length of dry fabric is passed at full-width through a high-temperature bath of dye solution and then run through padded rollers that evenly distribute the dye and remove the excess liquid.
This method of dyeing actually takes place before the yarn is woven, allowing the fabric to feature multiple colors and patterns. Through this process, the yarn is wound around a tube-like beam that has holes in it, and then slid into a closed and pressurized vessel. The dye then fills the vessel and runs through the beam, escaping through the holes. As a result, the yarn is dyed from the inside out, and vice-versa.
Flat-Bed Screen Printing
This method of coloration allows for intricate designs of up to 11 colors to be printed on a single side of the fabric. In this process, the fabric design is reproduced on a set of fine mesh screens, one for each color used in the design. On each screen, the area of the design that is not supposed to be penetrated by a certain color dye is covered with a dye-resistant coating. The screen is then coated with the dye on the back, and is mounted above a flat-bed that carries the fabric along from screen to screen. A squeegee blade then presses the dye through the open areas of the screen and onto the fabric, where the color is applied.
After the fabric is woven and given its rich color and details, it undergoes two separate treatments to make the product safe, soft and absorbent. The first treatment is the addition of a softening agent. We use silicon in this process, not only because it is proven as the most effective softener, but also because it is demonstrated to enhance the absorbency of our fabrics. This treatment is followed by an antimicrobial finish, which is used to help prevent mold, mildew and the spread of harmful organisms.
After the wet treatment, the fabric undergoes extensive tumbler drying, which removes any dampness and gives it some added fluffiness and volume. The fabric then undergoes a process known as stentering, which stretches and straightens the fabric to smooth out any wrinkles or creases caused by the wet treatment and the drying process.
Cutting & Hemming
Once the fabric has been treated, it is ready to be cut and hemmed. Products that consist of side-by-side panels are first cut lengthwise and then hemmed longitudinally, using chain stitch sewing on the left and right side. Commonly, labels are sewn in during this lengthwise hemming. Fabrics are then cross-cut and stacked for cross hemming, in which the hems are first folded, and then sewn.
After the fabric is given its rich color, it can be sent to our embroidery facility, where intricate details can be sewn in, giving the product fine details and design that cannot be achieved with commercial dyeing or printing machinery.
Folding & Shipping
Once the hems have been sewn, the stacked product is folded and packaged for shipment from our campus to the comfort of your home.
Our product development begins with an analysis of the macro trends affecting our marketplace. We try to identify our consumer, and recognize the changes that may have impacted their lives from a cultural and socioeconomic point of view. We look at their ages, location, and spending habits, all in the name of understanding their emerging tastes and preferences.
After looking at the sweeping trends and demographics, we attempt to find the elements that will connect with each of our consumers on a deep personal and emotional level. We look at our full palette of colors, patterns and textures, and attempt to pinpoint the variations that will resonate with them on all levels.
Cutting edge innovation
Our state-of-the-art laboratory and product development facility works tirelessly to ensure that all of the products we manufacture are as effective and environmentally safe as possible. The research and findings of these facilities are continually integrated into our emerging product lines and manufacturing process, ensuring each collection surpasses the previous in quality and comfort, and that expectations on our campus and in your home remain elevated.
By combining innovation with research, we are able to conjure trend-setting designs for our next collection of home textile products. It is at this point that we head back to the cotton fields and begin the process yet again.