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How are towels made?

Every towel manufacture starts off with the question: “How can I make the best towel at the best price?” So many factors go into that decision process. We hand select each of our towels to represent the best of breed of the different attributes. If you are interested in shopping by these, follow the links below.

Ball of cotton:
Soil, weather, light and pests are factors that impact the quality of cotton. Cotton is graded by color, purity and length of the fiber (called a staple). Choosing the right grade of cotton to create a quality, moisture seeking hand towel, bath towel or bath sheet is a crucial step in the manufacturing process.

Ball of cotton being carded:
Once pure cotton is harvested and extracted from the husk, fibers are then carded. Carding is an advanced brushing process that removes debris, untangles and straightens thick cotton fibers to make them easier to spin into a absorbent cotton towel.

Cotton fibers often go through a combing process prior to being spun. This process eliminates shorter fibers which easily pill and removes impurities. The longer fibers that remain are spun into a high thread count yarns which produce towels with that are silky and strong. Egyptian cotton and Supima cotton are examples of high thread-count towels.

Spinning wheels have been vastly modernized over the years. Most fiber spinning is now mechanized. Cotton fibers are blown into a rapidly revolving drum. As this happens, the loose cotton fibers continually adhere to the end of a strand of yarn (visualize how cotton candy is made) that is constantly being pulled out of the drum.

The twist of a yarn tells you the number of times a strand of yarn is twisted together per inch. The amount of twist can impact the thickness, strength, absorption and durability of a yarn. Zero-twist is a new process that works to open up the fiber loops for added absorption.

When dyeing is performed after fibers are spun into yarn, it’s called yarn dyeing. There are many methods of yarn dyeing, however cotton is most commonly dyed in package form. Cotton yarn is softly wound, pulled though dye and excess water is removed.

Bath Towels are woven on looms that can both weave the body of the towel and the loop. The pull or length of the loop is adjusted to vary the texture and pattern of a towel to create fine detailing and jacquard, ribbed and waffle weave collections.

And for detailed information on towel care, be sure to read our Guide to Washing Towels.

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