How Is Yarn Converted Into Fabric? Steps & Techniques Simplified
Fabric Yarn
Fibres are natural or man-made substances that are used for making yarns. Some common fibres that are generally used to make yarns are wool, cotton, silkworms, etc. These fibres are interlocked to make a continuous length of it called yarn. Yarn, in simpler words, is a longer length of intertwined and interlocked fibres. Yarns are used in the process of textile, weaving, sewing, embroidering, ropemaking, crocheting, etc. You must have seen a thread roll. Yes, that thread roll is also a yarn which is used in sewing machines for sewing clothes. Different types of yarns are produced for a different purpose. For crocheting, a different type of yarn is used, a more woolly kind, while for embroidery, another different kind of yarn is used, not everything but also not very thick like wool.
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How is Yarn Prepared?
Yarns are generally made by spinning the fibres into yarn machines. These are made from both natural and man-made fibres. Most natural fibres are generally short in length, and that is why man-made or synthetic fibres were produced as they are of great length which makes it more conducive to spinning. Spinning is the process of taking out fibres from their sources and twisting and locking them to give them that interlocked texture. Filament yarns or the synthetic ones require more twisting than the natural ones. The quality of the yarn depends on the number of twists produced. Therefore, higher the number of twists, stronger is the yarn produced.
A wide variety of fibres are used to create yarns that we used for sewing, crocheting, weaving, etc. The most common fibre used for creating yarn is cotton that is produced from the cotton plants. These are very famous in the textile industry. Egyptian cotton, American cotton, and Pima cotton are one of the most famous types of cotton that are used for making yarn. Next common source of fibre for yarn manufacturing is the sheep. Wool is extracted from the sheep and spun into woollen yarn. The two most famous types of wool extracted from sheep are the Merino and Lopi wool type.
Another famous source for wool is the alpaca. Alpaca’s wool has very different characteristics from the wool extracted from sheep. When we talk about yarn fibre, we cannot forget silk. Yarn of silk is manufactured by extracting the silk produced by the larvae of the silkworm. The finest silk is produced by Bombyx mori, also known as the Mulberry silkworms. Today moth caterpillars are also used for producing silk. You must have seen a rope, right? Ropes are manufactured from the yarn produced by the hemp fibres. Hemp fibres are used in the fabrics and textiles industry. Synthetic fibres such as rayon, nylon and polyester are also used to produce yarns.
Types of Yarn
Apart from classifying yarns on the basis of their source of fibres, we can also classify the types of yarns on the basis of the number of twists or the number of strands there are.
Single Yarns: Single yarns, also known as one-ply, are yarns that consist of a single strand that holds fibres together with the least amount of twists. In the case of filaments, there is either the use of one filament (called monofilament) or more than one filament that is grouped together with the least amount of twist or even no twist. S-twist or Z-twist is more common in this type.
Ply Yarns: Ply yarns, also known as folded yarns, are made by twisted two or more single yarns together. A two-ply yarn is made by twisting two single strands together. A three-ply yarn is made by twisting three single strands together. The texture is harder than usual, and the final yarn produced is firmer.
Cord Yarns: Cord yarns are made by twisting ply yarns together. Cords usually follow the SZS twists. The cord yarns are used to make ropes or cables, etc.
Novelty Yarns: Novelty yarns are those yarns that are produced by applying special effects like slubs. Slubs is the intentional inclusion of lumps into the yarn to give a different and special look.
Textured Yarns: Textured yarns are usually the ones made from synthetic fibres. Texturizing the synthetic fibres work on the characteristics of transparency, colour, patterns, etc.
FAQs on Yarn to Fabric: Process and Types
1. What are fibres and how are they classified based on their origin?
A fibre is a thin, thread-like strand from which yarn and, subsequently, fabrics are made. Based on their origin, fibres are classified into two main categories:
- Natural Fibres: These are obtained from plant or animal sources. Examples include cotton (from the cotton plant), jute (from the jute plant), wool (from sheep), and silk (from silkworms).
- Synthetic Fibres: These are man-made fibres created using chemical processes. Examples include polyester, nylon, and rayon.
2. How is yarn made from raw cotton fibre? Explain the key steps.
The process of making yarn from raw cotton fibre involves two primary steps: ginning and spinning.
- Ginning: First, the cotton bolls are picked from the plants. The fibres are then separated from the seeds by a process called ginning. This was traditionally done by hand but is now mostly done using machines.
- Spinning: After ginning, the mass of cotton fibre is drawn out and twisted. This process of spinning converts the loose fibres into a strong, continuous thread called yarn. Simple devices like the hand spindle (takli) and the spinning wheel (charkha) are used for spinning.
3. What are the two main methods for converting yarn into fabric?
The two main methods used to make fabric from yarn are weaving and knitting. Weaving involves arranging two sets of yarns together at right angles to each other to make a fabric, typically on a machine called a loom. Knitting involves creating fabric by forming interlocking loops from a single yarn, which can be done by hand with needles or by machine.
4. What is the key difference between weaving and knitting?
The key difference lies in how the yarns are used. In weaving, two distinct sets of yarns (the warp and the weft) are interlaced at right angles to form the fabric. In knitting, a single continuous yarn is used to form a series of interlocking loops. This difference also affects the fabric's properties; woven fabrics are generally firm and less stretchy, while knitted fabrics are more flexible and elastic.
5. Why are synthetic fibres like polyester often blended with natural fibres like cotton?
Synthetic fibres are often blended with natural fibres to create fabrics that combine the best qualities of both. For example, a poly-cotton blend is popular because:
- The cotton provides comfort, softness, and breathability.
- The polyester adds strength, durability, and resistance to wrinkles and shrinking.
6. Apart from cotton, what is another important plant fibre and what are its main uses?
Another important plant fibre is jute. It is a long, soft, shiny fibre that is one of the most affordable natural fibres. Jute fibre is obtained from the stem of the jute plant. Due to its coarseness and strength, it is not typically used for clothing but is widely used for making practical items like gunny bags, ropes, mats, and carpets.
7. Why is the process of ginning essential before spinning cotton fibres?
Ginning is essential because raw cotton bolls contain both fibres and seeds. If the seeds are not removed, they would act as impurities. Attempting to spin yarn with seeds would result in a weak, lumpy, and uneven thread that would easily break. Therefore, ginning is a crucial purification step that ensures a clean, uniform mass of fibre suitable for spinning into a strong, smooth yarn.
8. How did people in ancient times make clothes before the invention of modern fabric-making techniques?
In ancient times, before the invention of tools like the spinning wheel and loom, people used materials directly from their environment. Early humans used large leaves, the bark of trees, and animal skins or furs to cover their bodies. As agricultural communities developed, they learned to weave twigs and grass into mats and baskets. Eventually, they discovered how to twist natural fibres like cotton and flax into long strands and weave them into simple fabrics by hand.
