We regard it as completely normal, to buy and wear ready-made clothes whenever we please. Online platforms and technological developments have made clothing within arms' reach. Despite this fact the fundamental process of field to fabric and fabric to shirt remains the same. In this article we explain the fundamental producing process in six steps.

1. Cotton plantations

The cotton plant (Gossypion) requires plenty of heat and water. That is why cotton plantations are found primarily in countries with a warm climate. After sowing and waiting for several months, you have a field of fully-grown cotton plants.

The cotton is then picked, either by hand or machine. This machine separates the cotton fibres from the cotton seeds. The cotton fibres are used to produce cotton fabric. The seeds of the cotton plant are then sown again, or used to make cottonseed oil.

2. Spinning the cotton

Spinning is the first step in textile production. The cotton is developed into workable yarn. The structure of the yarn is determined during this process. It may be constructed entirely of cotton, or combined with synthetic fibres. Synthetic fibres are manufactured by means of a chemical process.

Spinning takes place on a machine that twists the fibres together. Therefore, this process is also known as spinning yarn. The structure of the fibres determines what spinning method is used. Spinning of yarn takes place in a spinning mill. The mechanism of a spinning machine is the same as when done by hand, only it is far quicker and more efficient in terms of production.

3. Plying and twisting of cotton

Often, spun yarns are too thin or weak, so two single threads are twisted together. This process is known as “plying”. The plied yarns then form the foundation of the fabric. The threads can be twisted together in different ways.

The method of twisting determines the structure of the yarn, as well as the finish when the yarn is spun into cloth. In addition, there is a difference between carded and combed cotton (and/or wool). Carded cotton/wool has a fluffier look and is coarse to the touch. Combed cotton is softer and more compact, with a smoother finish.

4. Weaving fabrics

Different methods of weaving produce entirely different fabrics, despite being made from the same material. The structure and method of spinning also play a role in this. Fabrics are woven on looms nowadays. A number of yarns are drawn at right angles to one another on the loom, the warp. Yarns are then threaded horizontally through the warp, the weft.

This mechanical method enables high speed weaving and the ability to produce a broader weaving width. Different types of fabric are produced by using different weaving techniques to combine the warp and weft to create a fabric.

5. Dyeing, printing and finishing

There are different methods for dyeing fabrics; it can be done at any time during the process. Textiles can be dyed as fibres, yarns or as a complete garment. For example the basic fabric can be treated by dyeing it and applying a finishing layer, or designs can be applied with printing techniques.

Cloth dyeing involves the use of equipment such as a jigger, reel, jet or nozzle dying machine. Or the product is dyed in a tumbler (a sort of spin dryer) of which the drum turns with the cloth in the dye bath. The cloth is submerged in the dye bath using different techniques. Time and temperature are important elements of the dyeing process.

6. From fabric to shirt

This last step completes the ‘field to fabric’ process. Buyers consider various aspects when procuring cloth. Tailors are particularly interested in the quality of the yarn, because that determines the quality of the fabric. The weaving technique (type of fabric), structure of the yarn, weight and colour also play an important role.

Different fabrics can be used to produce various end products. This may also determine the preference for a particular type of fabric. Having selected, in this case shirt fabric, a pattern is chosen. The fabric is cut according to the pattern and sewn into a shirt. The production of shirts may take place in large factories, or they may be made-to-measure by hand.

Tootal fabrics offers an endless choice of quality fabrics for various end products. View our collection here. Please feel free to contact our sales team!