Terry Towels

Fiber Preparation & Spinning

The process starts with selecting raw fibers, most commonly high-quality cotton, which are then blended, carded (straightened), and combed to remove shorter fibers. The resulting material is spun into strong, consistent yarn, often with low twist for the loops to enhance absorbency and a higher twist for the ground structure for strength

Warping & Sizing

The yarns for the length of the towel (warp threads) are wound onto large beams. The yarns are then "sized" or coated with a protective solution (like starch) to give them strength and durability to withstand the tension and friction of the weaving process

Weaving

The sized yarn beams are loaded onto a specialized terry loom, which uses two warp systems: a tightly tensioned ground warp for the base and a loosely tensioned pile warp to form the characteristic loops. A special reed mechanism pushes groups of weft threads into place, forcing the slack pile warp into loops.

Forming to Packing Process

Wet Processing (Dyeing & Finishing)

After weaving, the fabric, which is in a continuous, rough, off-white roll (greige fabric), is prepared for finishing

Desizing, Bleaching, and Washing

The protective sizing is washed off, and the fabric is bleached to achieve a pure white base

Dyeing

The large rolls of fabric are immersed in large, pressurized vats of chemical dyes and then steamed to set the color permanently.

Drying and Softening

The dyed fabric is dried, often in industrial tumble dryers, which helps fluff the loops to give the towel its signature soft feel

Cutting, Sewing, and Quality Control

The continuous fabric roll is measured and cut into individual towel sizes. The edges are then hemmed or lock-stitched to prevent fraying and provide a clean, durable finish. Quality control inspectors examine each towel for defects before it proceeds to the next stage.

Packaging

Finally, the approved towels are hand-folded, and automated equipment forms a bag (often plastic) around them. Labels (like UPC codes) are attached to the packaging, and the finished products are boxed and sent to a stock room for shipment

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