Cotton towels have long been cherished for their exceptional absorbency, softness, and durability. This comprehensive guide will delve into the manufacturing process of our Belem cotton towels, highlighting the benefits of cotton and its significance in creating high-quality towels that offer luxurious comfort and optimal functionality, only for you!
The Step-By-Step Manufacturing Process
Cotton Fiber Selection
Cotton is a natural fiber derived from the cotton plant's seed pods. Different varieties of cotton are available, each with unique characteristics. We choose our cotton from combed cotton, which is one of the higher-quality yarns available.
Long-staple cotton has longer fibers, known as staples, which contribute to the softness, strength, and durability of the resulting towels. These longer fibers enable our towels to maintain their shape and absorbance over time, making them a preferred choice for high-end Belem cotton towels!
Spinning and Yarn Production
Once the cotton fibers are harvested, they undergo the spinning process to transform them into yarn. The spinning process involves drawing out the cotton fibers and twisting them together to create a continuous strand. This strand of twisted fibers is known as yarn, which will serve as the foundation for the towels.
During spinning, the yarn can be further processed to achieve different thicknesses, strengths, and textures, depending on the desired final product. Our spinning process is incredibly detailed and made sure that these cotton fibers become fine and flexible to undergo the weaving process. The quality and characteristics of the cotton yarn play a significant role in our standard!
The cotton yarn is then woven together using specialized looms to create the fabric for the towels. Moreover, our Belem towels are typically woven on air-jet looms which make longer cotton loops on the surface of the towel.
Now, air-jet looms are an incredible and state-of-the-art weaving technique which promise softness and uniformity. However, these looms only require the most fine and high-quality cotton yarn as any thick pieces will break immediately during the process. The loops made from the air-jet looms are responsible for the towel's absorbency and plushness.
Dyeing and Printing
After weaving, the cotton fabric undergoes a dyeing or printing process to add color and patterns to the towels. After the procedure, the towels become a beige color, which is their natural state and is referred to as greige fabric. We bleach and dye our towels to maintain the amazing white color or prep it for any other color. Care is taken during the dyeing and printing process to ensure even color distribution and consistent quality throughout the fabric.
Cutting and Sewing
Once the fabric has been dyed or printed and inspected for quality, it is cut into towel-sized pieces. These pieces are then meticulously sewn to create the final towels. The edges of the towels are hemmed and finished to prevent fraying and ensure durability. We sew our towels with double needles and a minimum of seven stitches to ensure strength and to prevent unraveling, which also give it the complete luxurious look!
In the finishing stage, the cotton towels undergo several processes to enhance their softness, absorbency, and overall quality. These processes include washing, tumble-drying, and ironing. Washing removes any impurities or residual chemicals from the fabric, while tumble-drying fluffs up the fibers, increasing the towels' plushness and absorbency. Ironing or pressing ensures a smooth and wrinkle-free appearance.
And that’s it! Your Belem towels are prepped and ready for you to experience a five-star atmosphere only in the comfort of your own home!
Benefits of Cotton Towels
Cotton towels are renowned for their superior absorbency. The natural properties of cotton fibers, especially long-staple combed cotton, allow them to quickly and effectively soak up moisture, making them ideal for drying off after bathing or swimming.
Softness and Comfort
Cotton is known for its softness, and cotton towels provide a gentle and cozy feel against the skin. Long staple cotton fibers, with their longer and finer strands, create a luxurious texture that becomes even softer with each wash. This ensures a pleasant and comfortable experience when using cotton towels.
Cotton is a strong and durable natural fiber, making cotton towels highly resilient. They can withstand frequent use, regular washing, and the rigors of everyday life without losing their shape or integrity. This durability ensures that the Belem cotton towels last longer, providing value for money.
Our cotton towels are easy to care for, requiring simple washing and drying routines. They can be machine-washed and tumble-dried without losing their softness or absorbency. Additionally, cotton towels tend to resist stains and odors, further simplifying their maintenance.
Now, You Know. What’s Next?
Cotton towels are highly regarded for their exceptional absorbency, softness, durability, and overall comfort. The manufacturing process ensures the production of premium-quality towels that meet the demands of discerning consumers. To get authentic Belem towels, visit our website or contact us now!