From Masterbatch to Finished Yarn: Our Yarn Stage

Whether two batches match in colour is often decided before weaving — at the yarn stage. These are the steps we control there. These yarns are woven into fabric: see yarn-dyed upholstery fabrics.

Incoming inspection: rejected if non-conforming

The colour difference of the POY masterbatch yarn is checked from the moment it leaves the POY line. Non-conforming material is not accepted.

Texturing: one colour, one machine

POY to DTY follows a fixed process, and a given colour is textured on the same machine, so machine-to-machine variation does not enter the colour.

Tri-colour DTY and multi-colour fancy yarn

Tri-colour DTY is more demanding: POY batches and colour codes must be strictly separated, and the three colours are textured together from three POY colour codes. Fancy yarn twists more than a dozen colour codes into a single yarn — colour separation at the machine is the hardest part.

Chenille: steaming and cutter maintenance

Before chenille production, the DTY must be steamed through. Steam-box temperature, volume and duration have strict requirements and are set per article. The cutters on the chenille machines are replaced on schedule — they directly determine the feel of the pile, and this is one of the most easily overlooked factors in chenille production.

Note: process parameters (steaming, texturing and twisting settings) follow the confirmed order specification. Batch colour-difference data is available on request.

Related: quality control — every roll inspected ｜ solution-dyed fabrics ｜ SGS test reports