Raw Material Preparation
Select 40S/2 double-ply cotton yarn or synthetic yarns such as polyester or nylon. Warp yarns require sizing with a mixture of PVA and acrylate (in a 6:4 ratio) to enhance yarn strength and reduce the likelihood of breakage during weaving.
Weaving
Equipment Selection: Air-jet looms are typically used for mass production; rapier looms are suitable for small-batch, multi-variety production; and water-jet looms can be used for standard product categories.
Weaving Characteristics: Modified plain weaves (such as weft-rib or basket weaves) are employed. For standard products, warp and weft densities are controlled at 200×100 threads per inch, and the reed width for luggage fabric is usually set at 210 cm.
Dyeing and Finishing
The greige fabric undergoes a sequence of processes: fabric preparation, pretreatment, dyeing, and drying. Strict control is maintained over the dyeing pH value and temperature ramp-up curve to ensure uniform, colorfast results, while keeping fabric shrinkage within 3%.
Functional Finishing
PU or PVC coatings can be applied as required, with thickness controlled between 0.02 mm and 0.05 mm, enabling the fabric to withstand hydrostatic pressure exceeding 5,000 Pa. Additional specialized treatments-such as sanding, flame retardancy, or UV resistance-may also be applied. Finally, the fabric undergoes heat setting and quality inspection before leaving the warehouse.
