COTTON’S JOURNEY...FROM PLANT TO FABRIC


Cotton surrounds the seeds of the cotton plant. The natural properties of the cotton fibre make it easy to spin into a strong yarn. Each seed is surrounded by many single cotton fibres, which look like very fine hairs. Beneath these lies a second layer of short, fuzzy fibres. These are known as linters.

Cotton fibres are not straight, but actually spiral like a twist in a rope that is being held by two people twisting in opposite directions. These twists mean that the fibre surface is rough, so when a number of fibres are placed together, they interlock and twist. This makes cotton so suitable for spinning into yarn.

The new world cottons have longer fibres than their old world cousins. This means they can be spun into finer and stronger yarns. Almost all of the cotton grown today is of the new world variety.

There are many processes between Cotton plucking from the plants to making them into the end product. Let's take a brief look on these stages.

Cotton harvesting - where the cotton balls are plucked from the plants and packed into bales and sent to a ginning factory.

Ginning - where the majority of the unnecessary plant material are removed from the cotton balls and the majority of the cotton obtained is baled and sent to a spinning factory. The few remaining deficiencies in the ginned cotton is next removed and the yarn is wound into a big package. This is the raw material for the weaving mill.

Yarn spinning factory - It is then taken to a spinning mill where it is opened in a series of machinery called blowroom. The lap from blow room is further opened in a carding machine. The output from card called the sliver, is attenuated and made parallel in draw frames. It may or may not be combed to remove the short fibres and improve its quality. Then it is twisted into a rove and finally into a “Yarn”. Yarn of different counts, that is yarn of different diameter and quality can be manufactured based on requirements.


Weaving - the yarn procured from spinning units are passed through weaving preparatory processes known as warping and sizing and then loaded on a weaving machine, where the fabric is manufactured.

Hundreds and thousands of yarn are wound onto a beam in a sheet form. These may be coated with size paste and dried before weaving. Another thread is wound onto a small package called pirn. It is placed within a narrow thin wooden box with pointed ends called the shuttle. The shuttle is passed between the sheet of divided warp from the beam in a loom. This produces a fabric.


Further finishing - based on the end use for the fabric, the fabric is directly sold as greige material from the loom, or chemically processed to be sold as different finished fabrics. Different finishing processes could be bleaching, dyeing, anti-wrinkle finishing, anti-flammable finishing.

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