WIDE WALE CORDUROY

Make the base of the ridge from the warp and weft threads.

Making corduroy begins by interweaving threads arranged in the vertical direction and threads threaded in the horizontal direction.
Unlike regular textiles, some of the weft threads that will later become ridges are suspended above the surface of the fabric.
When the corduroy comes out of the loom, there are still no ridges that you normally see on corduroy.
The horizontal threads floating on the surface are cut in the vertical direction in the next process.
A delicate foundation for that purpose is being created here.

Cut the weft thread vertically to create ridges.

On the surface of the woven fabric, the weft threads that form the ridges remain connected.
Pass the guide needle under the weft yarn floating on the surface, and cut the yarn in the vertical direction with a circular thin cutter placed along the needle.
The work of passing the guide needle through is done manually for each row of ridges.
By cutting open the floating weft threads, three-dimensional ridges unique to corduroy are created.

Fluff up the ridges with plenty of water.

After cutting, there is some glue left on the fabric that was added to the warp threads to make it easier to weave.
First, pass the fabric through hot water at approximately 80℃ several times to remove the glue.
After that, carefully knead the dough in plenty of water.
This process is not just for washing fabrics.
By rubbing it in water, the pile that has been cut open will loosen and the ridges will stand up.
At the same time, the entire fabric becomes softer.
We use plenty of water and time to bring out the original three-dimensional feel of corduroy and a texture that makes you want to touch it.

The heat of the flame makes the outline of the ridges stand out.

After kneading the dough in water, it is passed through a number of drying rollers to adjust its twists and condition while drying.
Then, bring the fabric close to a heated roller to burn off any excess fuzz remaining on the surface.
By finely adjusting the distance to the fabric and the speed at which it passes, the surface of the ridges is beautifully prepared without damaging the plump pile.
After burning, wash the fabric again.
Rinse off any burnt or residue and dry again.
Once the surface of the fabric has been prepared in this way, it is ready for final dyeing. Wearing
colors, the corduroy is finished with three-dimensional thick ridges and an elegant luster.