Cotton Velvet Fabric Production: Complete Circular Knitting Machine Guide
Cotton velvet is a specialized knitted fabric known for its soft texture, excellent appearance, and premium feel. Producing high-quality cotton velvet using circular knitting machines requires precise control of loop formation, yarn selection, shearing processes, and dyeing procedures.
This guide explains the complete cotton velvet production process, including machine setup, yarn requirements, loop control, shearing, and finishing best practices.
Cotton Velvet Fabric Production Methods
Cotton velvet fabric is typically produced using two main methods:
Method 1: Reverse Terry Knitting and Shearing Process
In this method:
The fabric is first knitted using a reverse terry circular knitting machine
The loops are then cut during the shearing process
Recommended loop height:
2.5–3.0 mm loop height (optimal range)
If the loop height is too low:
Loops cannot be cut properly
Velvet effect is inconsistent
If the loop height is too high:
Excessive material loss occurs during shearing
Typically, greige fabric undergoes two shearing passes:
First pass: removes most loops
Second pass: ensures uniform velvet surface
This process ensures consistent fabric quality.
Method 2: Direct Loop Cutting on Circular Knitting Machine
This method uses specialized loop-cutting circular knitting machines that cut loops directly during knitting.
Advantages include:
Improved production efficiency
Reduced processing steps
Consistent velvet surface
This method is commonly used in modern textile production.
Yarn Selection for Cotton Velvet Fabric Production
Proper yarn selection is critical for velvet quality.
Common Loop Yarn Specifications
Typical loop yarn:
18 tex cotton yarn
Alternative options:
17.5 tex cotton yarn
15 tex cotton yarn
Higher-quality velvet fabrics use combed cotton yarn, which provides:
Better appearance
Improved softness
Higher fabric quality
However, combed cotton yarn increases production cost.
Carded cotton yarn is more economical but may cause:
Cotton nep
Fiber irregularities
Reduced fabric appearance quality
Ground Yarn Selection
Common ground yarn options include:
Polyester filament yarn
Cotton yarn
Cotton-polyester blended yarn
Blended yarn example:
80% cotton + 20% polyester
Blended yarn provides:
Improved durability
Better fabric stability
Enhanced production efficiency
Alternative Fiber Options
Modal and viscose fibers are also widely used.
Advantages include:
Brighter dyeing results
Better luster
Softer hand feel
Improved fabric performance
Blended yarn with more than 50% cotton is recommended for optimal performance.
Importance of Yarn Twist Uniformity
Uniform yarn twist is critical for consistent loop formation.
If yarn twist varies between feeders:
Loop height becomes inconsistent
Shearing becomes uneven
Velvet surface quality decreases
Maintenance recommendation:
Use yarn with consistent twist specifications
Ensure yarn quality control before production
Loop Formation and Fabric Structure Control
Proper loop formation ensures high-quality velvet surface.
Important factors include:
Loop vertical alignment
Loop tip sharpness
Consistent loop height
If loop tips are not properly formed:
Shearing becomes inefficient
Fabric quality decreases
The ground fabric structure should ensure proper coverage and stability.
Improper ground yarn coverage may cause:
Increased shearing loss
Incomplete velvet surface
Fabric rejection
Shearing Process and Quality Control
Shearing is a critical step in velvet production.
Common shearing defects include:
Uneven shearing
Vertical streaks
Circular blade marks
Incomplete shearing
Fabric holes
Proper machine adjustment and maintenance are essential.
Maintenance recommendations:
Ensure blade sharpness
Maintain proper shearing alignment
Monitor shearing tension
Dyeing Process Considerations
Dyeing quality directly affects velvet fabric performance.
Typical dyeing methods:
Light colors: cotton-only dyeing
Medium and dark colors: cotton and polyester dyeing
Key recommendations:
Minimize re-dyeing
Avoid excessive reprocessing
Repeated dyeing reduces velvet softness and fabric quality.
Benefits of Proper Cotton Velvet Production and Machine Maintenance
Proper production and maintenance provide:
Improved fabric quality
Reduced defect rates
Increased production efficiency
Reduced machine wear
Extended machine lifespan
Conclusion
Producing high-quality cotton velvet fabric using circular knitting machines requires precise control of yarn selection, loop formation, shearing processes, and dyeing procedures. Proper machine maintenance, correct yarn specifications, and optimized production parameters ensure consistent velvet quality and improved manufacturing efficiency.
Implementing these best practices helps textile manufacturers achieve superior fabric performance and reduce production costs.
Post time: Mar-03-2026