Did you know that 99% of fabrics on the market lose 30% of their quality before they are even woven? This is due to the spinning process.

When it comes to making excellent fabrics, the spinning process plays an essential role. It is through this stage that fibres and filaments are transformed into yarns, ready to be woven into beautiful fabrics. Spinning is a complex process that requires expertise and meticulous attention. Every detail counts, from the meticulous selection of fibres to the various stages of treatment and transformation.

Stage 1: Processing - Selecting excellent fibres

Opening allows the fibres or filaments from the bales to be decompressed, opened and cleaned of certain impurities. 99% of mills use automated methods to process fibres, which reduces production costs. However, it is difficult to remove all the impurities present in the fibres. That's why our mills distinguish themselves by adopting a manual approach. Our experts work meticulously to select the most qualified fibres, carefully removing all impurities. This meticulous process ensures that only the highest quality fibres are used for spinning, resulting in excellent finished textiles.

Stage 2: Carding - Perfectly opening the fibres

99% of mills simply separate and parallelise fibres and filaments at this stage, reducing costs and speeding up production. However, our experts stand out as being among the mills that use carding as an extension of the opening stage. Our experts know the importance of guaranteeing excellent fibres, which is why they use this stage to continue opening, untangling and aerating the fibres, removing even more impurities. Once this process is complete, the fibres are completely separated and parallelized, ready to be transformed into yarns of exceptional quality. This meticulous approach contributes to the production of top-of-the-range textiles that meet the most demanding standards.

Stage 3: Stretching - Achieving perfect homogeneity

The stretching process stretches the combed card web to achieve greater uniformity. While 99% of mills use a two-stage process, consisting of preliminary stretching followed by final stretching, our mills stand out by adopting a three-stage process. Our approach includes preliminary drawing, intermediate drawing and final drawing. This additional method guarantees fibres and filaments of the highest quality and strength. By drawing more progressively, we can ensure better yarn homogeneity, improve yarn strength and produce textiles of excellence.

Stage 4: Roving - The key to ring spinning

In the textile spinning process, the roving stage plays an essential role in ring spinning. While 99% of mills neglect this stage in order to reduce costs, we work with mills that recognise its crucial importance. The roving process consists of producing a roving from a drawtape. This step makes it possible to reduce the size of the ribbon while inserting a false twist into the roving. The roving is then wound onto a bobbin which feeds the ring spinning process. By incorporating this essential step, we ensure that we produce yarns of excellence, which is reflected in the durability and strength of our finished textiles.

Stage 5: Spinning - The art of creating exceptional yarns

In the textile spinning process, the spinning stage is decisive for the strength and quality of the yarns. While 99% of mills favour spinning methods such as air-jet or open-end to increase yield and reduce costs, these techniques reduce the tensile strength of yarns by more than 30%, compromising their strength. The mills we work with, on the other hand, use the ring-spinning method, which puts the yarn through a severe test in order to give it its strength and durability, which explains why optimum quality fibres and filaments are needed to use this method. The resulting yarn is wound onto a bobbin. This stage gives the yarn its final characteristics, such as titre and twist (usually Z-shaped).

Stage 6: Winding - A luxury for achieving excellence

Winding is a luxury that only ring-spinning mills can afford. Winding involves transferring the yarn from the bobbins to a cardboard tube. At this crucial stage, the yarn is meticulously analysed electronically to detect and eliminate any defects. In addition, if necessary, the wire can be waxed to improve its properties. Unfortunately, 99% of mills neglect this stage in order to cut costs. On the other hand, the mills we work with attach great importance to winding. This approach ensures that only top-quality yarns are selected, guaranteeing excellent finished textiles.

Stage 7: Dubbing - Excellence beyond expectation

Doubling is an optional but essential step to further improve the physical characteristics of the yarn, such as its strength and appearance. Doubling involves multiplying the yarn by doubling or even tripling it. Unfortunately, 99% of mills neglect this step in order to reduce costs. But the mills we work with recognise the importance of doubling.

Stage 8: Twisting - Consolidating the structure

The twisting stage is essential after doubling the yarns. While doubling consists of placing two or three yarns side by side, twisting involves twisting them together to obtain a single, stronger, more resistant yarn. This operation improves the cohesion of the yarns and strengthens the structure of the final yarn. Twisting can be carried out using different techniques, such as simple twisting, twisted twisting or loop twisting, depending on the desired characteristics of the yarn. This is a key stage that contributes to the excellence of the textiles obtained.

Stage 9: The expedition - Towards new horizons

In the textile spinning process, the shipping stage plays a crucial role in getting the yarns to the weaving machines. Once the yarns have been carefully wound onto bobbins, they are ready to be shipped to the weaving mills. These spools of yarn are delivered with care, guaranteeing their integrity and preserving their excellence. On the weaving machines, the yarns will be woven together to form fabrics of excellence, renowned for their exceptional durability. This final stage of shipment ensures a seamless transition between the spinning and weaving processes, resulting in remarkable textiles.

A meticulous spinning process for excellent fabrics

99% of fabrics don't achieve excellence because they are manufactured to reduce costs and achieve high yields. We offer you the remaining 1% of fabrics that will stand up to mankind's greatest adversary, time. Did you know that some pieces of excellent fabric can last for decades, even centuries? Some ancient fabrics have been found in archaeological digs in perfect condition, a testament to their exceptional quality and durability.