7 Exclusive Terry Towel Manufacturing Process

Md Mahedi Hasan

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Terry towel fabric consists of long loops and it is able to absorb a decent quantity of liquid. Sustainable loop piles can be found on either one or both sides of the product, and they can generally cover the entire surface, as well as form stripes, checks, and other patterns.

The word “terry” originates from the French word “trier,” which means to pull out, and refers to the old method of making absorbent materials in which the fibers are taken out by hand. Terry Towel are typically rather intricate, with yarns of a wide variety of qualities and hues combined with many loop piles and flat structures of varying types.

What is Terry Towel?

Terry towels, contrary to popular opinion, are utilized not just in bathrooms but also in other commercial sectors such as car washes, construction, and beauty salons.

Towels made of terrycloth are long-lasting, in addition to being absorbent and versatile. Because of these factors, terry towels are particularly well-suited for use in body washing.

Terry Towel
Figure: Terry Towel

Have a experienced in terry towels produce, we classify towels for various applications according to the overall performance of the towels, which is determined by the number of inches, sizes, and types of cloth used in the production of the towels.

Different Types of Terry Towels

  1. Bath Sheet
  2. Bath Towel
  3. Guest Towel
  4. Face Towel
  5. Washing Gloves
  6. Kitchen Towel
  7. Institutional Towel
  8. And Many More Towel items.

After we washing one’s face and hands, a standard function for wash towels is to pat dry the front and the arrows. The towel’s dimensions may vary slightly from manufacturer to manufacturer, but overall, it is one of the tiniest types available.

Because it comes into contact with the delicate areas of the skin, such as the face and the hands, we check that it is comfortable and free of harmful substances. The other kind of towel comes in hand towels, much like the latter. After getting out of the shower or tub, one will use a bath towel to pat their entire body dry.

While we are manufacturing this type, we make sure that its absorbency is increased to its full potential and that it dries in a short amount of time. The sole difference between the bath sheet and the bath towel is that the bath sheet is slightly more expensive. It is the standard practice in hotel rooms and other guest accommodations.

Terry Towel Manufacturing Process

Terry Towel Manufacturing Process

1. Spinning

In this procedure, we select fibers that are turned into towel yarns of appropriate counts. Some toweling factories make their yarns.

Before passing through the blow room line, fibers are mixed according to plan and subjected to atmospheric conditions, following the mill’s mixing strategy. Before mixing passes via the blow room line, the mix plan determines which machines to use and their settings.

Terry Towel Spinning Process
Figure: Terry Towel Spinning Process

Once blow room results are achieved, fibers are fed directly into carding machines and transformed into slivers. These carding slivers are evaluated for technological characteristics before proceeding. Frame-making. Set according to the working plan, these draw frames blend and parallelize fibers. If parameters are passed, draw frame slivers are processed. Semi-combed draw frame slivers are supplied to roving frames (Speed frame).

Slivers are spun into specified-hank rovings. The roving bobbins are then put into ring frames with well-set technological parameters, where they are turned into yarn counts for terry towels.

Ring bobbins feed automatic winding machines, which package the yarn. These winding machines can be adjusted per the spinning plan.

Single yarns are treated on TFO machines to make double yarns with the requisite twist factor and direction for terry towels.

Preparing a spinning strategy requires a lot of spinning knowledge. Spinning plan defines yarn parameters and quality, requiring strict process control procedures that We ensure control laboratory oversight.

2. Weaving

To make terry cloth requires a particular machine that can weave the fabric. It goes for two sets of warp yarn in a terry loom, one for the ground and one for the pile.

Terry Towel Weaving Process
Figure: Terry Towel Weaving Process

Warp yarn for the environment, and the pile is unwound from two separate beams. Bobbins are used to hold the lengths of weft or filler yarns. Weaving involves threading ground and pile yarn through the heald eye or harness and special double-ended terry-reed needles to create a finished piece of cloth.

3. Warping

The needed weave, total number of ends, length, and needed warp density (EPI) of the fabric should be used to determine how the warp ends should be coiled onto the section beam. We use both Direct distortion or the Sectional warping approach. The direct warping system can be used in cases where the creel capacity is adequate, but the number of total warp ends required is not very significant.

4. Formation of a pile

The thickness of the towel’s pile is one of the most critical factors in determining how well it will absorb water and how well it will perform its other functions. The quality, weight, and other factors, depending on the requirements, determine the loop’s length. The yarn utilized by pile producers is of a higher quality and may be combed, compact, hydro, or zero-twisted.

Since, We have 40% market share in Canada, 20% in USA, and 20% in Europe, to achieve more excellent absorbency and lint properties, piles are constructed using a variety of high-value fibers, such as special kinds of cotton. For instance, suvin, Giza, Pima, bamboo, and modal, amongst others. To achieve more robustness and compactness in the ground fabric, considerably coarser counts are utilized for the ground yarn in both the OE and 2-ply options.

Warping, sizing, and drawing are the three stages of preparation identical for both piled and ground yarns.  Towel production follows the identical process sequences to the manufacture of other textile items, such as shirts, suits, and sheeting textiles. These sequences include de-sizing, bleaching, dying, and finishing.

5. Inspection of grey

After the towels have been woven in looms. Then their production is checked for quality using process control, the towel rolls are subsequently cut according to the specification sheet, and then they are taken to the inspection room.

From the storage area of the inspection room, selected quality rolls that have passed for quality according to the processing plant are transported to the process house, where bleaching and dying operations will take place.

6. Bleaching

These selected rolls are transferred to the bleaching section using the recommended trolleys. Once there, they are bleached in a machine called a J-Box machine, which is a continuous bleaching process. The material is bleached using a variety of different methods, including the application of hydrogen peroxide, caustic defoamers, and other components.

Both the reaction time and the speed of the machine need to be set according to the process plan that was created after considering all of the activity parameters. After the roll has been breached, it is put through several cycles in the washing machine to remove any residue of the chemicals that may still be present on the fabric.

The rolls are then dried before being transported to dye house. To ensure that the rolls can be identified at any time throughout the processing and storage processes, all of the procedural requirements are adhered to.

7. Dyeing

Bleached rolls are then carried to the organic dye house, where they are subjected to dying operations of various colors following the dye house’s planning sheets, as per the required order from the dye house.

Dried rolls that have not been cut are transported to dyeing machines, and dyed with vat color utilizing vat dye receipts. This has been shown, over time, to produce colorfast toweling after being subjected to intensive domestic laundering.

It is then put through a series of washing machines and given an extensive wash to ensure no traces of chemicals or dye particles that have become loose are left on the cloth. The maximum towel manufacturing facility has a dyeing capacity of around 1,50,000 kg which helps to ensure top performance.

After that, the rolls are placed in a machine that uses air to dry them, and then they are transferred to a section that handles folding, cutting, and folding products. The roles can be identified at any point since all procedural standards are adhered to. This helps to prevent any mix-ups during the processing stage as well as the final storage stage.

Quality control of Terry Towel Manufacturing

The quality assurance department plays a significant role in monitoring, checking, and controlling each activity and operation involved in the manufacturing process, beginning with the receipt of all raw materials and continuing through to the final shipment of products. This is regulated by having online process control and an offline quality control laboratory to keep a careful eye on things while actively participating in their operations.

Quality Parameters

a. Weight & GSM: Towel Industries produce high GSM’s Terry Products. The importance and the GSM should be the same as what the customer requires. Towel makers compute things like the height of the pile, the density of the picks and ends, and other factors to ensure their products are up to standard using some template or software called an ERP.

This database, along with any other software, was constructed using some fundamental calculations. The skilled and expert team of Towel Industries is able to produce 200-1000 GSM towels with various types of fancy borders.

b. Dimensional Stability: Product has the high dimensional stability. The behavior of a towel after it has been washed is an example of one of the properties that come under dimensional stability. The percentage of residual shrinkage in a towel after it has been finished is used to determine dimensional stability.

c. Softness: We produce super soft terry towels. The softness and hand feel of the pile are determined by the qualities of the yarn used to make the pile, the finishing chemicals, and to some extent, the bank’s orientation.

d. Orientation of pile: The direction of the pile is wholly determined by the process line.

e. Lint: Lint is essentially projecting fibers that are present in a towel after it has been finished. During the testing process, the amount is evaluated based on the weight of the accumulated yarn collected from the washing machine and the tumble dryer.

f. Absorption: Terry has a higher absorption capacity. A Terry towel should have a very high capacity for soaking up water.

g. Other: Strength, color fastness, and other characteristics are available in Terry Towels.


comprehensibility and suppleness of terry fabric are particularly notable. All premium qualities are essential for achieving a higher level of physical comfort. Materials used for surface drying or rapid water transfer from wet body surfaces require a high level of water absorbency to function correctly.

Towel Industries must have a robust quality assurance department that can coordinate with the production line. With the help of workers offering continual crucial quality product information before being put to use in the production process, all raw materials, components, and other items that were purchased to begin the manufacturing process are placed through a significant quality check.

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