Microfiber Cloth

Microfiber splitting: This process consist in altering the fibers by increasing the pH in large drums. By subjecting the fabric to an alkaline solution, the woven yarn is splitting, thus significantly increasing its contact surface.

Dyeing: Immediately after splitting and sometimes as part of a combined operation, the fabric is placed in large vessels, together with high quality pigments. The vessels are then pressurized and heated. Most vessels are steam heated, some are electric. The dyeing process ends with a rinsing cycle. All pigment residues and chemicals are collected and neutralized in large decantation tanks.

Drying and tensioning: At the end of the dying process, the microfiber fabric is placed on a long horizontal machine which has a dual purpose. The fabric is running through the entire length of the machine, about 200 feet, to keep it at a constant tension while drying, which is very important to maintain the proper geometrical characteristics of the fabric, all the way to the finish product.

Cutting: Rolls of fabric are unrolled in layers on top of one another, either by hand, or using an automatic machine. Depending on the type of fabric and the stability of the weave, there can be up to 150 layers. The top layer is then marked at specific intervals and a grid template drawn. The last step of this process is to cut at once through all of the layers with a vertical fabric blade.

Sewing: Individual pieces are surged, by adding a piping material and sewn on their entire perimeter. During this step a sew in label is inserted in the surging. The purpose of the label is to display the brand name, composition, sometimes care instructions and other information useful for the end user.

Pigtails removal: When surging is done by hand, the operation of sewing around the towel is very fast. The operator needs to make sure that the entire towel is properly sewn and can't stop exactly at the corner. Usually the surging extends for an inch or two beyond the corner, creating a "pigtail". The surplus of piping around the towel is cut with a hot wire.

Final Inspection: A visual inspection makes the final determination if the product is suitable for packaging or not. If yes, bundles corresponding to the sell unit pack quantity are prepared, if not the individual piece is removed from the line and its sew in label cut off, a clear indication that the product is not suitable for retail as new.

Packaging: Depending on the product, the sell unit could be packed in a clear polybag, a polybag with graphics, a clam shell, a cardboard box, a sleeve, the combinations are endless. A group of sell units is then placed into master cases to protect the product as well as to facilitate the transportation process.