Production Process

Warp finishing is the process of spooling thousands of cotton yarns to be sized and dyed onto a bearing called warp beam by way of wrapped bobbin upon a warp finishing machine. A piece of denim fabric is interwoven with at least thousands of cotton yarns and the warps among them are dispersed into dozens of warp beams consisting of hundreds of yarns to facilitate sizing and dyeing.

To be processed using the combined sizing and dyeing machine; usually called slide staining and accomplished along with dyeing. In the process, the cotton yarn would pass through the soaking tank and the dyeing tank at a constant speed of about 24-30 m/min repeatedly for multiple soaking and dyeing, so that a layer of serous film and desired color would form on the yarns. The sizing of the yarns is mainly aimed to appress the filoplume of the yarns and prepares the yarns for the loom by increasing their strength.

A process where weaving shafts after drafting are placed on the loom for weaving. The weaving can also be divided into five steps: heald lifting, wefting insertion, opening, reeling, and warp pacing, each to be completed by different mechanisms. The rapier loom is popular for its fast operation, accurate wefting insertion, and strong beating force, leading to full and tight fabric width. The company currently has 192 Picano 220 gamma rapier looms imported from Belgium.

In the process of textile printing and dyeing production, surface defect is one of the important factors affecting the quality of the fabric, so the inspection of surface defects is an important part of fabric production.