Everybody enjoys a good fleece blanket. They are perfect for any day of the year, depending on the type of blanket we use, and can be quite comforting. However, the process of making them is quite a long one, with many details to cover. Let’s see how fleece blankets are made and get a better understanding of the manufacturing process they go through.
The fabric, color, and knitting approach are considered
The first step toward making a fleece blanket is deciding what type of blanket we’ll make. In this step, picking the proper fabric to make the item from and choosing the approach is the most necessary concern.
When it comes to picking a fabric for a fleece blanket, there are a ton of choices. From cotton to plush, there are over a dozen options. This is an important choice because the fabric the blanket is made out of heavily influences its properties. Whether it’s the softness of the blanket or how easy it gets covered in pills, it’ll be impacted by this choice.
Color is a simple decision. The color of a fleece blanket gives it its unique appearance. There are a ton of options in this area because of the possibilities to mix and match colors.
Preparing yarn
Even when we pick the type of fabric that will be used and the color of it, we need to prepare yarn. It is required to properly prepare either DTY or FDY yarn before being used for the creation of fleece fabric. DTY stands for polyester drawn textured, and this yarn type is made when polyester is both twisted and drawn at the same time. FDY, otherwise known as fully drawn yarn, is produced by a process that spins the fabric at a higher speed in combination with intermediate drawing. It will be quickly stabilized and optimized for use on fleece fabrics.
Our choice should be driven by the most suitable yarn for the specific weight and size of the blanket. As noted in the design process, the details of the actual blanket will be a key factor in this choice.
Knitting
The next process of making the fleece blanket is actually knitting it. The approach to knitting may differ based on the design and type of yarn we use. Choosing certain designs may require certain knitting styles to properly do it.
Whether by hand or by machine, the knitting will be done by consistently applying a certain pattern to form a fleece blanket. The fleece blanket will vary in softness, elasticity, weight, and so on, depending on the choice of knitting style we choose. Looking through the available options on locations like zjmanew.com may give you a rough idea of how these items can differ, flannel blankets will be quite different from sherpa blankets.
Dyeing and printing patterns
The chosen colors that have been set aside before and the design elements for our patterns will come into play now. If we are using a solid color design, it will probably contain a single dye that will be applied on both sides of the fabric to provide an even color to the fleece blanket.
If there are designs or patterns present, we will need to apply certain printing techniques. Either for screen printing or digital printing, something that’s also dependent on the type of fabric that’s used.
In the case of patterns, we may also apply a different knitting approach that will properly split up the colors of the blanket. Otherwise, we could use specific pattern covers for dyeing parts of the blanket that have different colors.
Sizing and extra details
There are cases where the same blanket type will be ordered. In order to speed up the process, it’s possible to knit and dye the fleece fabric itself and then cut it to fit the design we are looking for.
Whether by hand or laser cutting machine, it’s possible to cut out the correct designs for the ordered blankets. The process needs to be done correctly in order to cut in a straight line, which allows blankets to be folded easier and fit better on a bed.
Any extra embroidery, logos, artwork, or any other design detail that requires extra work is done after sizing cuts. The proper location picked during the design choice will be used, and the extra details will be inserted through embroidery machines. Some simpler printed designs and logos will be immediately printed on the blanket instead.
Sewing and hemming
Sewing and hemming together the roughly finished blankets can be achieved with a multitude of sewing machines. With these machines, the process is made far easier and more accurate. By hemming stuff, we will be able to increase the durability and appeal of the blanket.
Sometimes these machines require specific stitches that enhance the connections between the edges. On top of that, it is possible to close over and round out the rest of the blanket, making it more durable on the edges.
Finishing it up
The next step is all about wrapping up the process. Any form of extra cutting and sewing happens during this process. Whether it’s because of malfunctions during the process or just a simple manufacturing mistake, problems will get corrected during this step.
Loose threads or bits and pieces of the fabric that have been left in the fleece blanket will be vacuumed and cleaned now. During the process, most if not all imperfections are removed to make the blanket as comforting and appealing as possible.
Quality control and packaging
After cleaning up, the fleece blanket enters the last part of manufacturing. This is where the blankets are inspected and cleared for delivery. If a blanket doesn’t conform to quality regulations, it will be put aside while those that manage to pass it are sent to packaging and shipping.
The blanket is now just a few steps away from leaving the manufacturing process. It just has to be secured and labeled before being put in the package. After that, fleece blankets are put out for shipping to stores or homes, depending on the way the company handles sales.
