By Leonie Barrie 20 December Font size Email Print. Interest in the sector is being spurred by its low-cost and reliable power supplies, easy access to ports and, of course, close proximity to high-quality raw cotton - the US is the world's third-largest supplier after China and India, and its largest exporter. As well the benefits of spinning the yarn near to the source of its raw material, US producers are able to take advantage of regional trade pacts that offer preferential duty treatment on finished products made with US materials.
Dear readers! Our articles talk about typical ways to solve the issue of renting industrial premises, but each case is unique.
If you want to know how to solve your particular problem, please contact the online consultant form on the right or call the numbers on the website. It is fast and free!
Production of yarnVIDEO ON THE TOPIC: Cotton to Yarn Process -- Yarn Manufacturing Process -- How Make Yarn from Cotton -- wayfarer bd
Gaffney Manufacturing, National Textiles, Cherokee — clangorous, dusty, productive engines of the Carolinas fabric trade — fell one by one to the forces of globalization.
Just as the Carolinas benefited when manufacturing migrated first from the Cottonopolises of England to the mill towns of New England and then to here, where labor was even cheaper, they suffered in the s when the textile industry mostly left the United States.
It headed to China, India, Mexico — wherever people would spool, spin and sew for a few dollars or less a day. Which is why what is happening at the old Wellstone spinning plant is so remarkable. Bayard Winthrop, the founder of the sweatshirt and clothing company American Giant, was at the mill one morning earlier this year to meet with his Parkdale sales representative. Just last year, Mr. Winthrop was buying fabric from a factory in India. Now, he says, it is cheaper to shop in the United States.
Winthrop says American manufacturing has several advantages over outsourcing. Transportation costs are a fraction of what they are overseas. Turnaround time is quicker. And while Mr. Winthrop did not run into such problems, monitoring worker safety in places like Bangladesh, where hundreds of textile workers have died in recent years in fires and other disasters, has become a huge challenge.
Instead, he said, the road to Gaffney was all about protecting his bottom line. That simple, if counterintuitive, example is changing both Gaffney and the American textile and apparel industries. While the size of operations remain behind those of overseas powers like China, the fact that these industries are thriving again after almost being left for dead is indicative of a broader reassessment by American companies about manufacturing in the United States.
In , the M. Forum for Supply Chain Innovation and the publication Supply Chain Digest conducted a joint survey of of their members. The survey found that one-third of American companies with manufacturing overseas said they were considering moving some production to the United States, and about 15 percent of the respondents said they had already decided to do so.
Beyond the cost and time benefits, companies often get a boost with consumers by promoting American-made products, according to a survey conducted in January by The New York Times.
The survey found that 68 percent of respondents preferred products made in the United States, even if they cost more, and 63 percent believed they were of higher quality. But as manufacturers find that American-made products are not only appealing but affordable, they are also finding the business landscape has changed. Two decades of overseas production has decimated factories here. Between and , on average, 17 manufacturers closed up shop every day across the country, according to research from the Information Technology and Innovation Foundation.
Now, companies that want to make things here often have trouble finding qualified workers for specialized jobs and American-made components for their products. Take Parkdale: The mill here produces 2. In , that production level would have required more than 2, people.
When Bayard Winthrop founded American Giant, he knew precisely what he wanted to make: thick sweatshirts like the one from the Navy that his father used to wear.
Winthrop had already produced sportswear overseas, so he looked there for the advanced techniques and affordable pricing he needed. With the help of a consultant, he settled on a mill in Haryana, India, that could make the desired fabric.
After several months of back-and-forth, Mr. Winthrop was ready to ship his first sweatshirts in February But he was frustrated with the quality, and the lengthy process. By October of last year, Mr. Winthrop had moved production to South Carolina.
Now it takes just a month or so, start to finish, to get a sweatshirt to a customer. Nowhere close. Time was foremost among them. The Indian mill needed too much time — three to five months — to perfect its designs, send samples, schedule production, ship the fabric to the United States and get it through customs.
Winthrop was hesitant to predict demand that far in advance. There were also communication issues. Winthrop would send the Indian factory so-called tech packs that detailed exactly what kind of fabric he wanted and what variations he would allow. But even with photos and drawings, the roll-to-roll variance was big. But it had stopped making sense. Now that production has shifted to the United States, Mr. Winthrop says those problems have disappeared. Winthrop and his team visit Carolina Cotton Works and Parkdale whenever they want, check on quality and toss ideas around with the managers.
And, he says, the cost is less than in India. Where Mr. Winthrop relies on labor — the cutting and sewing of the sweatshirts, which he does in five factories in California and North Carolina — is where the costs jump up. But truth be told, labor is not a big ingredient in the manufacturing uptick in the United States, textiles or otherwise.
Indeed, the absence of high-paid American workers in the new factories has made the revival possible. Step inside Parkdale Mills, and prepare to be overwhelmed by machines.
The ceilings are high and the machines stretch city block after city block — this one tossing around bits of cotton to clean them, that one taking four-millimeter layers from different bales to blend them. Only infrequently does a person interrupt the automation, mainly because certain tasks are still cheaper if performed by hand — like moving half-finished yarn between machines on forklifts. Beyond that, there is little that resembles the mills of just a few decades ago.
Not here. The air-cleaning room, where air is washed 6. Along the ceiling, moving racks like those at a dry cleaner snake throughout the factory, carrying the finished yarn to a machine for packaging and shipping. That machine has enough lights and outlets on it that it resembles a music studio soundboard.
Founded in , Parkdale is the largest buyer of raw cotton in the United States. In the s, when its current chairman, Duke Kimbrell, took over, it was a single plant with a couple of hundred workers. Seeing that other plants in the area were streamlining their businesses and ceasing to make their own yarn, Parkdale supplied yarn to nearby manufacturers like Hanesbrands.
Business flourished, and Parkdale acquired competitors and soared until the s. The North American Free Trade Agreement in was the first blow, erasing import duties on much of the apparel produced in Mexico. The Asian financial crisis in the late s, when currencies collapsed, added a 30 to 40 percent discount to already cheaper overseas products, textile executives said. China joined the World Trade Organization in and quickly became an apparel powerhouse, and as of , the W.
In , American-made apparel accounted for By , it accounted for 2. Over all, the American manufacturing sector lost 32 percent of its jobs, 5. The textile and apparel subsectors were hit even harder, losing The company began meeting with machine manufacturers, doing trial runs of equipment and offering feedback and debugging, so it got dibs on the newest technology.
It looked for business opportunities in the countries where its customers were heading, those in Central America in particular, and now 75 percent of its business is in exports. Over all, the company employs 4, people, its biggest work force ever, but it is technology that has made it competitive. Warlick said. We compete with them on technology and productivity.
All that automation has made working in the mill — which once meant mostly dead-end jobs for people with no other options — desirable for many people. Howard Taggert, 86, got his first mill job in after high school. Taggert, who is African-American. We made a living. He started by opening cotton bales, which involved striking an ax onto a metal tie around the bales — a dangerous job, given that a spark from metal striking metal could ignite a room full of cotton.
He was paid 87 cents an hour. The work was so bad that Mr. Taggert refused to let his children go into mill work. He might be surprised to hear about Donna McKoy, who went back to work in a mill even after earning an associate degree in criminal justice.
The sense of desperation was palpable, Ms. McKoy said. After a headhunter contacted her in , she became a supervisor at Parkdale, overseeing a night shift of 11 workers. The work — and the workplace — are barely recognizable compared with her job a decade ago.
A couple of things struck her right away. First, the mill was clean. Second, Ms. McKoy got training. For her first eight months, Parkdale paid for hotels, food, dry-cleaning and gas for trips home as she rotated around different factories and learned all of the jobs. And there were fewer people. McKoy now works at a plant in Walnut Cove, N. On a typical hour shift, Ms. She recently bought a three-bedroom house and owns a car. Still, some Parkdale employees worry about the future.
Cord yarns are made by twisting together two or more ply yarns. Textile manufacturing is a major industry. Yarn Manufacturing Process The process of separating the seeds and debris from the cotton fibers is known as ginning. Eh, from what I've been told, it's very common for yarn manufacturers to do this. Lycra yarn and its properties.
Ginners and Exporters of Raw Cotton & Cotton Yarn
Yarn is a long continuous length of interlocked fibres , suitable for use in the production of textiles , sewing , crocheting , knitting , weaving , embroidery , or ropemaking. Modern manufactured sewing threads may be finished with wax or other lubricants to withstand the stresses involved in sewing. Yarn can be made from a number of natural or synthetic fibers. Many types of yarn are made differently though.
Connect with Cotton Yarn Dyeing Factory Experts for your Project, Phone Consult or Job
This image is no longer for sale. It has previously been bought for a multiple re-use license which is still valid. You cannot download or purchase for any new licenses. By clicking OK, you are confirming that this image is only to be used for the rights in the existing license. Shopping cart Download packs.
Cotton fabric is one of the most commonly used types of fabrics in the world. This textile is chemically organic, which means that it does not contain any synthetic compounds. Cotton fabric is derived from the fibers surrounding the seeds of cotton plants, which emerge in a round, fluffy formation once the seeds are mature. The earliest evidence for the use of cotton fibers in textiles is from the Mehrgarh and Rakhigarhi sites in India, which date to approximately BC. The Indus Valley Civilization, which spanned the Indian Subcontinent from to BC, was able to flourish due to cotton cultivation, which provided the people of this culture with readily available sources of clothing and other textiles. While the Ancient Chinese relied more on silk than cotton for the production of textiles, cotton cultivation was popular in China during the Han dynasty, which lasted from BC to AD. Before this point, Europeans believed that cotton grew on mysterious trees in India, and some scholars during this period even suggested that this textile was a type of wool that was produced by sheep that grew on trees.
Cotton and Synthetic Yarn
Gaffney Manufacturing, National Textiles, Cherokee — clangorous, dusty, productive engines of the Carolinas fabric trade — fell one by one to the forces of globalization. Just as the Carolinas benefited when manufacturing migrated first from the Cottonopolises of England to the mill towns of New England and then to here, where labor was even cheaper, they suffered in the s when the textile industry mostly left the United States. It headed to China, India, Mexico — wherever people would spool, spin and sew for a few dollars or less a day.
Yarn is a strand composed of fibres, filaments individual fibres of extreme length , or other materials, either natural or man-made, suitable for use in the construction of interlaced fabrics, such as woven or knitted types. The strand may consist of a number of fibres twisted together; a number of filaments grouped together but not twisted; a number of filaments twisted together; a single filament, called a monofilament, either with or without twist; or one or more strips made by dividing a sheet of material, such as paper or metal foil, and either twisted or untwisted. The properties of the yarn employed greatly influence the appearance, texture, and performance of the completed fabric. Fibres are units of matter having length at least times their diameter or width. Fibres suitable for textile use possess adequate length, fineness, strength, and flexibility for yarn formation and fabric construction and for withstanding the intended use of the completed fabric. Other properties affecting textile fibre performance include elasticity, crimp waviness , moisture absorption, reaction to heat and sunlight, reaction to the various chemicals applied during processing and in the dry cleaning or laundering of the completed fabric, and resistance to insects and microorganisms. The wide variation of such properties among textile fibres determines their suitability for various uses. The first fibres available for textile use were obtained from plant and animal sources. Over a long period of experimentation with the many natural fibres available, cotton , wool , jute , flax , and silk became recognized as the most satisfactory. The commercial development of man-made fibres began late in the 19th century, experienced much growth during the s, expanded rapidly after World War II , and is still the subject of extensive research and development.
Get Latest Price. Recognized worldwide as the industry leaders for spun Yarns, we have perfected our spinning processes by applying state of the art automated technology and innovation in every phase of our yarn manufacturing process. We believe that quality products are not only by promises but also by proven results. Development of new textile products is done through Innovation in defining production processes of higher quality and making available modern technologies and professionals with the highest level of competence. View Complete Details.
Also in blends of Poly-Viscose and Acrylic Viscose. Mercerization is done mostly for cotton fibers to improve the strength, affinity to dyes and luster properties. Synthetic yarns are mostly made from polyester, elastane, and acrylics. It is a synthetic fiber widely popular due to its elastic nature. It is also known as Lycra. The count ranges from 20D to 70D. It is a synthetic yarn prepared by using chemical compounds. The yarn has S twist pattern with 2 Plied arrangements. The acrylic yarn count ranges from Ne10 to Ne
US cotton yarn sector attracts increased investment
Textile manufacturing is a major industry. It is based on the conversion of fibre into yarn , yarn into fabric. These are then dyed or printed, fabricated into clothes.
We can provide you detailed project reports on the following topics. Please select the projects of your interests. The scope of the report includes assessing market potential, negotiating with collaborators, investment decision making, corporate diversification planning etc. NPCS is manned by engineers, planners, specialists, financial experts, economic analysts and design specialists with extensive experience in the related industries.
Need Help? I have good experience in cotton yarn dyeing and mixtures I previously commissioned 2 Obermier yarn OK Yarn dyeing is reasonable, I guess for the local market. I have no idea of the potental of your C