RASCHEL PRODUCTION
YARN PROCESS
The first step of our production process is the preparation of yarn beams specifically designed for each fabric group.
These beams, tailored on a product basis, are created using yarns with various denier and filament structures. By utilizing polyester, elastane, and blended yarns in different proportions and thicknesses, the performance characteristics of the final fabric begin to take shape already at the warping stage.
Our warping machines, equipped with high-precision tension control, wind different types of yarn in a balanced manner, laying the foundation for the desired surface characteristics and strength values in the subsequent stages of production.
The homogeneity achieved during the warping process is a key factor in ensuring critical properties such as elasticity, wrinkle resistance, and surface stability.
Our fabric portfolio covers a wide range of products, including highly stretchable crinkle and bubble textures for apparel, wrinkle-resistant fabrics that retain their shape, breathable and lightweight mesh tulles, bridal tulles in varying weights and transparencies, and mosquito nets designed for technical applications.
Each of these fabric types is customized through the selection of yarn deniers and warping settings during the warping stage, ensuring the most suitable technical foundation for their intended performance and end-use.
PRODUCTION PROCESS
Following the preparation of yarn beams through the warping process, the second stage of production—Raschel knitting—begins.
In this phase, the warp yarns are converted into fabric by forming loops in both horizontal and vertical directions.
Our Raschel knitting machines are equipped with varying numbers of guide bars, enabling the production of a wide variety of fabric patterns and structures.
Raschel knitting technology is based on the principle of guiding warp yarns through needles according to specific pattern movements.
This structure enables the production of fabrics with both high manufacturing efficiency and superior surface quality.
Multi-bar Raschel machines, in particular, are preferred for the production of stretch fabrics, crinkle and bubble textures, mesh tulles, and decorative patterned tulles.
Yarn Feeding: Each warp beam is positioned onto the corresponding guide bar of the machine, and the tension of each yarn is individually controlled.
Loop Formation: With the help of needles (tricot or compound needle systems), the warp yarns form loops based on the movement of the guide bars. The lapping settings of the bars determine the fabric’s structure and pattern.
Pattern Formation:
Using jacquard or pattern templates, complex designs can be created on multi-bar machines.
Fabric Tension and Feed Control:
The fabric take-off tension is automatically monitored to ensure consistent weight (gsm) and fabric density.
Cooling and Surface Stabilization:
Fabrics exiting the high-speed knitting machines are passed over cooling drums to balance surface tension and prepare them for subsequent processes.
Fabrics produced with Raschel knitting technology include:
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Highly stretchable fabrics for sportswear and outerwear,
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Wrinkle-resistant and comfortable textile products,
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Voluminous and puffy bubble fabrics,
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Lightweight, transparent, and patterned tulles,
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Technical meshes used for mosquito nets and filtration applications.
Thanks to our high-capacity German and Korean-origin Raschel knitting machines in our production line, we are able to achieve both high-volume output and customized production tailored to specific customer demands.