Chenille Manufacturing

Compared to many other manufacturing processes, Chenille has a wider arrange of yield and twist variations. As you will find below, this is a new standard for count or yield testing. These tolerances are based on a 25 meter sample length measurement using standard practices for tension control, which is regulated in humidity conditions as well as normal conditions. The twist tolerances are as follows: 

International Specification for Chenille Count and Twist Tolerances

There is a two-step process for manufacturing Chenille fabric. The first step is when Chenille is place onto Chenille bobbin. The second step involves the rewinding of the Chenille onto a dye tube or cone. Then an electronic clearer is located in the yarn path of step two to detect the lengths of the yarn that the pile may have missed. Once the electronic clearer has detected a section of the missing pile greater than the minimum setting specified, a cutter is electronically activated. The cutter then cuts the yarn and the winder operator pulls the yarn back to cut out the missing pile section. The operator also reties the yarn and continues winding the package. At this time, the electronic clearer devices are almost 100% effective. 

Splicing or knotting Chenille is not a simple thing to do because you have to be very careful that you do not cause a defect in the article when doing this task or you will have bigger problems arise. Unfortunately, you cannot just tie a regular knot and be done with it. You must use one of two methods to insure fantastic results. The first method is tying a core knot. This can be done by stripping back the pile of both ends and sufficiently tying a double square knot in the core yarns. 

This specific method requires extreme caution when holding the twist in the yarn ends where the pile starts. After the knot has been tied, the ends are clipped close to the small knot. Then the pile ends are pushed over the knot for the final result. If method two is applied, a splice must be created. To create the splice, the two ends must overlap 1 to 2 inches and then a mechanical wrap-around splicing device will wrap the yarn. The wrap yarn can be either a very fine yarn of the same fiber as the Chenille pile or a fine monofilament nylon material. 

Another part of the process is creating piles that lie in one direction. Once Chenille has been woven into fabric, it reflects the light in a different direction. This is known as the reflection effect and is one of the most desirable characteristics that Chenille offers. In addition, strict control of the pile direction must be in order and be maintained during the entire Chenille manufacturing process.