Ever wondered what it takes to create a piece of sustainable, high-quality loungewear that feels incredibly soft to the touch, yet is durable enough for everyday wear? Let's pull back the curtain on the production process of our Setcomforts organic cotton clothing, as we take you on a journey from farm to fashion, highlighting our ethical and sustainable practices every step of the way.
From Farm to Fiber
Our journey begins in the cotton fields, where sustainable farming practices are at the heart of our supply chain. We partner with farms that adhere to the international standard for environmental management systems. This ensures that our raw materials are not only of the highest quality, but also produced responsibly, with constant efforts to measure and improve environmental impact.
Once harvested, the cotton is sent to the gin where the seeds and debris are carefully removed. This is done using roller gins that are specifically designed for Extra Long Staple (ELS) cotton, like the kind we use, to maintain the fiber's quality and length. After ginning, fiber samples from the cotton bales are graded based on length, strength, fineness, uniformity, and color.
From Fiber to Yarn
After the cotton has been cleaned and graded, it's time to spin it into yarn. We employ a combination of carding and combing machines in this process. This not only results in high-quality yarn but also contributes to the final features of the cotton fabric.
One of the key steps in our yarn production process is combing the cotton. This might sound like a tedious task, but it's what sets our garments apart. The combing process removes short staple fibers, which has a direct effect on the fabric's pilling resistance.
You might wonder, what is pilling? Well, pilling occurs when loose fibers begin to push out from the fabric, often caused by wear and tear and forming small, unsightly balls on the surface. By using a combed yarn, we eliminate the fibers that are most likely to cause pilling, ensuring your Setcomforts garments maintain a smooth, clean look wear after wear. This is also why organic combed cotton is a better option for sensitive skin.
But the benefits of combing don't stop at pilling resistance. Combed fibers are also cleaner, stronger, and have a superior luster compared to carded ones. You see, carding is an important initial process that disentangles, cleans, and aligns fibers. However, it does not remove all short staple fibers. These fibers, included in the carded yarn 'web', can make the yarn less smooth and more prone to breakage.
When you choose Setcomforts, you're choosing garments made from combed yarn, which is less hairy and offers a higher luster than carded yarns. This results in a finer, stronger thread and ultimately, a smoother, more comfortable fabric that stands up to washing and wearing without compromising on look and feel.
This commitment to quality at every stage of production is just one of the ways we ensure that your Setcomforts clothing is a cut above the rest.
From Yarn to Fabric
The next stage of our production process involves knitting the yarn into fabric. At Setcomforts, we primarily use two different knitting methods: jersey knit and rib knit.
What is Jersey Knit
Jersey, also known as single knit, is one of the most commonly used forms of weft knitting. The fabric produced through this method is lightweight, breathable, and incredibly flexible, making it ideal for everyday wear. It has a smooth, flat face with distinctive right and wrong sides. When used in garments, the right side, characterized by vertical lines, is usually kept on the outside, and the wrong side, marked by horizontal lines, on the inside. Jersey knit is used for the body of our Supima cotton t-shirts, offering a smooth, soft texture that conforms comfortably to the body.
What is Rib Knit
Rib knit, on the other hand, is a double-faced knit characterized by vertical columns or ribs on both sides of the fabric. Thanks to the alternating knit and purl stitches, rib knit is highly elastic and retains its shape well, making it perfect for areas that require flexibility, like the cuffs and necklines of hoodies or the waistbands of sweatpants. Rib knit is used for our side ribbing, hem, neck, gusset, and cuffs in our fleece, offering a snug yet flexible fit that enhances comfort.
Each of these knitting methods has its own unique characteristics, contributing to the comfort, aesthetic appeal, and functionality of our garments. By choosing the right type of knit for different parts of the garment, we ensure that our pieces don't just look good, but also offer superior comfort and durability, living up to the high standards of Setcomforts clothing.
Garment Production: Quality and Consistency
Once the fabric is ready, it's time for it to be cut and sewn into garments. Our factories follow a stringent quality control process at each phase of production, ensuring consistent sizing and superior quality. With a focused product assortment and high production volume, we maintain a high level of consistency across all our products.
We place immense importance on the welfare of all our workers. The factories we partner with meet the social criteria set by the Global Organic Textile Standard (GOTS), which are based on key norms of the International Labor Organization (ILO), United Nations Guiding Principles on Business and Human Rights (UNGPs), and Organization for Economic Cooperation and Development (OECD).
Final Product: Quality You Can Feel
Our meticulous attention to detail at every phase of garment production and manufacturing ensures that you receive the highest quality organic cotton loungewear. At Setcomforts, we take pride in knowing that our customers appreciate the effort, dedication, and commitment to sustainability that goes into each garment. When you choose Setcomforts, you're not just opting for premium quality, but also contributing to a better planet.
By offering transparency into our production process, we aim to empower our customers. We hope that understanding the journey from farm to fashion will provide you with an even greater appreciation for your Setcomforts organic cotton loungewear. After all, the story behind your clothing is just as important as how it looks and feels.
