Because it is broad and extremely comprehensive, it is normal for questions to arise about the textile production chain, especially regarding how it works and the stages involved in this network.
With that in mind, we have gathered in this text the main information about the textile chain. In addition, we highlight some of the challenges and opportunities it faces, as well as tips on how to ensure growth in this scenario.
Keep reading to find out more!
How does the textile production chain work?
The textile production chain is simply a term that represents the connection of all links in the production process within the sector.
In other words, it begins with fiber production, through cotton farming, and goes all the way to fashion shows. Along the way, it passes through spinning, weaving, finishing industries, garment manufacturing, and retail.
In any case, the textile production chain is responsible for transforming fibers into yarn, yarn into fabric, and fabric into finished products.
Thus, it includes:
- Raw material producers;
- Chemical industry;
- Textile industries and operators;
- Manufacturers of textile equipment and machinery;
- Suppliers of inputs (dyes, pigments, etc.);
- Commerce;
- Final consumer.
What are the stages of the textile production chain?
To better understand how the textile production chain works, it is necessary to know its stages and learn how they function as links in the production process.
Check them out below!
1. Raw materials
This first stage of the textile chain is responsible for producing raw materials, which can be obtained in basically two ways:
- Fiber or yarn extrusion;
- Agricultural or animal-based fiber production.
In the first case, it refers to the development of artificial and synthetic fibers through the chemical industry.
According to an article on the subject, these fibers were created to meet the need for faster production and lower costs, reducing dependence on natural fibers in times of crisis or scarcity.
In fact, blending manufactured fibers with natural ones helps improve strength and durability, as well as making treatment and finishing easier and enhancing appearance.
Historically, Brazil was dominated by natural fibers. In 2019, Unoeste reported that the share of natural fibers had dropped from 78% to 47% of the total, reflecting the growth of synthetic and artificial fibers in the industry.
Even so, agricultural or animal-based fiber production is the most well-known and traditional segment of the sector. It refers to obtaining fibers from plant or animal sources.
Cotton, in fact, is the main raw material in the textile industry. Among natural fibers, it accounts for 97% of all consumption. As a result, it represents 46% of all fibers used by the textile industry.
2. Spinning
Spinning is the process responsible for transforming fiber into yarn. To achieve this, the following steps take place:
- Cleaning and opening of the raw material;
- Alignment of fibers to form a web;
- The web is thinned and transformed into a sliver;
- The sliver is processed on a drawing frame, stretched, twisted, and turned into yarn.
However, as noted in the aforementioned article, it is important to highlight that the spinning stage is generally carried out in an integrated manner. The goal is to optimize the process and ensure the industry operates in a strategic and competitive way.
For example, spinning is most commonly directly linked to weaving operations. It is also possible to observe integration between spinning, weaving, and finishing.
In any case, it is essential that this stage relies on smart solutions capable of ensuring the quality of the textile product.
After all, the material produced in this stage will be used in all other stages of the textile chain, making it essential that its production and storage guarantee consistency and reliability.
3. Weaving/Knitting
Weaving/knitting consists of the interlacing of the produced yarns. They are arranged in different directions, known as warp (lengthwise) and weft (crosswise).
From this process, it is possible to produce two basic types of fabrics: woven fabrics and knitted fabrics. The difference between them lies in the way the yarns are interlaced. For example, in woven fabrics, the structure is regular, using both yarn directions.
Knitted fabrics, on the other hand, are formed by interconnected yarns that provide vertical and lateral support. They are always made in the same direction, similar to the knitting process.
Read also: Weaving machines: relationship with quality control and optimization
4. Textile Finishing
Textile finishing is the stage of the production chain responsible for improving and adding value to the fabric. This process alters the physical characteristics of the material so it can be used for specific and specialized purposes.
To achieve this, several steps are carried out, divided into:
- Primary stage: responsible for preparing the material for dyeing and final finishing (pre-bleaching). This may include brushing, singeing, scraping, and other processes.
- Secondary stage: where the actual coloring of the fabrics takes place, using reactive dyes, pigments, and other techniques. This can be total (dyeing) or partial (printing). Printing can also be digital, a growing trend in the industry.
- Tertiary stage: enhances the fabric’s characteristics, aiming to improve shine and texture. For this, sprays, waterproofing agents, softeners, flame-retardant finishes, and others are applied.
Sample testing is also carried out at this stage to assess quality and dimensional stability, helping to prevent shrinkage, errors, and waste in the garment manufacturing phase.
Read also: Textile processing: find out how it adds value to the final product
5. Confection/Making
Confection/Making is the stage of the textile production chain that transforms finished yarn into final textile products. This includes clothing and footwear, as well as towels, home décor items, bed sheets, and more.
It is also possible to produce other types of goods that will be used in other industries, such as cotton filters and components for automotive interiors and packaging, for example.
In any case, this stage involves design, pattern making, layout, cutting, and sewing of the pieces. All activities required to transform the fabric into the final product.
6. Distribution and Commerce
Finally, the last stage is reached: distribution and commerce. This stage involves the collection of textile products, their storage, and all processes responsible for delivering the item to the end consumer or to the relevant industry.
What are the main challenges and opportunities in the textile production chain?
As you may have noticed, the output of each stage serves as the foundation for the next one.
The textile production chain is completely interconnected. Because of this, it is necessary to eliminate obstacles in order to achieve the full development of the industry.
The main challenges and issues in the sector include:
- Controlling production costs, balancing labor, raw materials, inputs, and resources;
- Waste and material losses between stages;
- Quality control;
- Optimization and performance across activities;
- Continuous monitoring of changes in consumer behavior.
At the same time, the main opportunities involve sustainability, customization, and customer experience. These are, in fact, consequences of current consumer behavior and market trends. After all:
- 87% of customers prefer brands that offer a good experience;
- 75% say companies with sustainable practices are more likely to win them as customers;
- 83% of people prefer personalized products.
In any case, the answer to overcoming challenges and seizing opportunities is one: textile technology.
Innovation is essential to meet the needs of today’s consumers. In addition, it contributes to the continuous growth of the industry and enhances competitiveness.
Automation, through smart machinery, enables high performance, scalability, standardization, and data-driven management. All of this results in:
- Cost reduction;
- Energy savings;
- Increased safety;
- Environmental preservation;
- Better preservation of textile products;
- Fewer errors and higher productivity;
- Elimination of textile waste;
- Greater business transparency, more accurate management, and improved information control;
- Increased customization and unprecedented scalability.
Regardless of the scenario, technology contributes to the efficiency of production processes in the textile chain. Modern equipment prevents rework and, consequently, reduces costs and production losses.
When it comes to textile technology, Delta is the answer!
The textile production chain is made up of interconnected stages. Errors in the spinning stage, for example, can have negative impacts on textile finishing.
It is necessary to ensure quality at every stage in order to eliminate the main challenges of the textile sector and, in turn, secure the major opportunities of today’s market. As we have seen, technology is the solution to this.
Innovative machines directly impact production profitability and performance. Therefore, they drive continuous improvement in products and services.
Delta provides textile solutions for the spinning, knitting/weaving, finishing, and garment manufacturing stages!
These solutions are developed based on the reality of the industry, aiming to increase your company’s productive capacity through data-driven insights and operational performance.
Learn more about Delta’s textile machinery now!
