Fleece Fabric || Dyeing, Finishing, and Testing Of 100% Cotton Fleece Fabric With A Complete Practical Experiment [UPDATE 2024]

Fleece fabric is a type of Knit fabric that can make from different fibers like wool, cotton, or other synthetic materials. It is a soft, lightweight fabric that is often used for jackets, blankets, and other clothing items. Fleece fabric is known for its warmth and comfort, and it is often used in colder weather climates. Some people think that “can I dye fleece fabric?’. The answer is yes, We can dye. Let’s discuss.

Here I am discussing the fleece fabric dyeing process, Dyeing flow chat, finishing process, finishing flow chart, and different testing. All the processes are 100% practical.

The specialty of fleece fabric:

• It is a three yarn special thick fabric.
• It is a super soft fabric.
• Durable and has high insulation value.
• This fabric is used to make jackets, sweaters, and blankets.

Complete (yarn to garments) target flow chart of fleece fabric:

Grey Yarn

⇩

Knitting

⇩

Dyeing

⇩

Finishing

⇩

Cutting

⇩

Sewing (Garments)

Let’s start my practical experiment which I did myself.

Target fleece fabric Parameter:

Buyer	Practical Textile
Fabric Type	Fleece
Composition	100% Cotton
Color Name	Been
Shade%	5.16%
Required Dia	175 CM Open
Required GSM	310
Special Note	Garments Wash

Yarn Information( By which I knitted this fabric):

Yarn count and Type	32/1 Organic cotton+12/1 Carded cotton
Yarn composition	100 % Organic cotton
Yarn lot	xyz+xyz
Yarn Brand	A reputed company

Knitting Parameter of target fleece fabric:

Machine  Dia + Gauge	30+20
Total needle	1882 Pcs
Stitch length	4.5+3.5+1.55
Machine No	XYZ
Machine Brand	Jiunlong
Machine RPM	19.5
Grey Width	107 cm Tube
Grey GSM	248
Gray Wash
Gray Wash GSM

Fleece fabric dyeing:

Dyeing 100% cotton fleece fabric is a special experimental procedure. Where it is dyed with a reactive dye and reactive dyeing process. Let’s start:

Flow chart of 100% cotton fleece fabric dyeing:

Grey fabric from knitting

⇩

Batching

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Load to dyeing machine

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Scouring+Bleaching

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Bio polishing

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Dyeing

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Soaping

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Softener

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Unload

⇩

Delivery to finishing

Batching:

Here I collect the grey fabric from the knitting department. Prepare the batch according to dyeing mache (No. of Nozzle and loading capacity). here we prepare a batch card that consists of all parameters of knitting, dyeing, and finishing. Now batch is delivered to dyeing machine.

Dyeing Recipe:

Here I create a recipe and calculate all the dyes and chemicals. I am showing you the brand name of dyes & chemicals. The given dyes % depends on the targeting depth of shade and chemical dosing depends on chemical supplier recommendation.

SL#	Name of the chemicals	G/Liter	%	Req’d Qty. In Kg	Issues Qty.	Remarks
Pretreatment :
1	Anticreasing agent	1.0
2	Detergent	0.80
3	Sequestering agent	2.00				98*50
4	Caustic soda	2.0
5	H2O2	2.50
6
7
	Peroxide killer	0.15
8	Acetic Acid	1.00
9
10
11
12
Dyeing :
13	Leveling agent	2.00
14	Anti creasing agent	2.00
15
16	Golden-yellow -ss		0.9%
17	Dy: deep –red -dr		0.66%
18	No: navy-wb		3.6%
19
20	Gluber Salt	80
21	Soda Ash Lt	20
After Treatment :
22	Soaping agent	0.80
23	Leveling agent	0.5
24	Anti creasing agent	1.00
25
26	Fixing agent	1.00
27
28	Softener	1.00

100% cotton fleece fabric dyeing process:

This process is like a 100% cotton fabric dyeing process. I discussed it in my previous article. Now I am showing you the process which I used for this batch. Process steps are below:

Scouring & Bleaching

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Detergent + Anti-creasing agent = Inject

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Temp 40⁰C= Fabric Load

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Caustic soda Dosing

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Temperature 60⁰C, Run=20 Min

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Temperature 70⁰C

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Sequestering agent + H2O2 Dosing 5 Minute

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Temp to  98⁰C & run= 40 Minute

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Cooling at 78⁰C

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Sample check

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If the sample ok then Drain

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Normal Hot 70⁰C, run =10min

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Peroxide killer  60⁰C, run=10 Minute

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Drain

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Naturalization with acid

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Control the ph=4.5 And temperatue=55⁰C

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The enzyme (Bio polishing) Inject

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Run for 50min

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Sample check (Check hairiness)

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If ok then raise the temperature to 80⁰C

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Run for 10min

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Drain

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Wash 10min

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Dyeing

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Control temperature 60⁰C

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Leveling PH check 6.20

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Leveling Dosing 60⁰C, Run= 3 Minute

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Color Dosing 30 Mints

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Runtime 20 mint

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Salt Dosing 10 Minute

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Runtime 10 Minute

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Salt Sample check + Fabric Quality Check

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1^st 1% Soda dosing 15 minute

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Runtime 15 minute

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2^nd 99% % Soda dosing 20  minute

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Runtime 20 minute

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Sample check If ok then

⇩

Bath Drop

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Normal hot 70⁰C run =10min

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Wash clear

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Ascitic acid inject to neutralize the batch

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Wash and drain

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After Treatment

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Soaping inject

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Rise the temperature to 90⁰C, Run=10min

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Drain and wash

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Dossing the fixing agent=5min

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Runtime=15Min

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Wash clear

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Ph control 5

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Softener Dossing 5min

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Runtime 10min

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Check the softness of the fabric, if ok then drain and fill

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Unload

⇩

Delivery to finishing department

Comments on dyeing:

It is so easy and basic process. To get dyeing faults free better results to follow the A to Z process. All dyes percentages will the according to your lab and chemical dosing depends on your chemical supplyer.

Finishing of 100% Cotton fleece fabric:

After completing the dyeing process fabric comes to the finishing department, to dry the fabric, and control the dia, GSM, and Shrinkage.

Flow chart of fleece fabric finishing:

Collect fabric from dyeing

⇩

Slitting

⇩

Stenter

⇩

Brush

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Sharing

⇩

Stenter

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Compacting

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Check all the quality parameters and sent the fabric to the testing lab

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If ok then delivery to cutting

Slitting:

This is the first process of finishing. The fabric is opened here. Because we have to use Open stenter and compacting machine. I am sharing the data which I got during slitting:

Machine Speed	30
Padder pressure	1.5 kg
Over Feed
Fabric In Diameter	169 Cm
Fabric Out Diameter	170 Cm

Stenter:

Name	Stenter	Dry Time
Width set	168
Over Feed	59%
Temperature	120
RPM/ Speed	14
Padder Pressure	3+2
Vibration	blank
Softener Type	Cationic
After Dry Width	200
After Dry GSM

Brushing:

L. Pile:	1.0/1.0
L.C. Pile	0.2/0.2
L. Tension	6/7
L. Drum RPM	100/90
U.Pile	0.3/0.2
U.C.pile
U. Tension	6/7
U Dram RPM	100/90
Machine speed	17

Stenter:

Name	Stenter	Dry Time
Width set	168
Over Feed	59%
Temperature	120
RPM/ Speed	14
Padder Pressure	3+2
Vibration	blank
Softener Type	Cationic
After Dry Width	175 for 175	B dia= 200
After Dry GSM	290 For 310	B. gsm=370

Compacting:

Stanter/Dryer		Compacting
Width set
Over Feed		Temperature	120
Temperature		Steam Pressure	30
RPM/ Speed		Width set	170
Padder Pressure		Over feed%	35%
Vibration		RPM/Speed	12
Softener Type		Compaction%
After Dry Width		After Width	175 f 154
After Dry GSM		After GSM	310 f 194
		Wash gsm	322

Shrinkage Test Report:

Final width=175   f 154                                    Final GSM=310 f 322

Shrinkage with tumble dry:

Length=-1.66 %

Width=-4.48%

SP%=2%

Shrinkage of line dry:

Length=-2.8%

Width=-8%

SP%=0%

Comments on overall finishing:

Palla wash Dia= 149 GSM=322

So that dia= -26cm Which is not good. Need to be careful during finishing and knitting parameters.

Testing of 100% cotton fleece fabric

There are many physical and chemical tests available in the world. No. of Test selection depends on the requirement of the buyer. Here the types of tests I have done, are listed below with results. all the tests and test results are actual. Overall comments on the testing will be at the end of the test.

Sl. No.	Test Name	Results (A)
01	Dimensional Change in Washing	Pass
02	Spirality After Washing	Pass
03	Color Fastness to Washing	Pass
04	Color Fastness to Rubbing	Pass
05	Color Fastness to Perspiration	Pass
06	Bursting Strength	Pass
07	Pilling Resistance	Pass
08	Mass Per Unit Area	Pass

01. Dimensional Change in Washing

Test Method : ISO 5077+ ISO 3759+ ISO 6330: 2012

Test Condition: Normal Program, Machine Wash@40°C, Tumble Dry, Used domestic washing machine Miele, 25 gram Ariel Reference  Detergent with 3.5kg load.

Sample (A)	After One Wash
Direction	Result	Client Requirement
Length	-2.10%	±5%
Width	0.80%

Remark: (+) Means Extension And (-) Means Shrinkage

02. Spirality After Washing

Test Method: ISO 16322-3: 2005

Test Condition: Normal Program, Machine Wash@40°C, Tumble Dry, Used domestic washing machine Miele, 25 gram Ariel Reference  Detergent with 3.5kg load.

Sample (A)	Result	Client Requirement
Spirality	0.0%	Max 4%

03. Color Fastness To Washing

Test Method: ISO 105 CO6-A1S:2010

Test Condition: Temperature at 40 degrees, Time 30 min, Detergent 4g/l ECE With 10 Steel Balls

Sample (A)	Result	Client Requirement
Color Change	4	3-4
Color staining		3-4
-Acetate	4-5
-Cotton	4-5
-Nylon	4-5
-Polyester	4-5
-Acrylic	4-5
-Wool	4-5

04. Color Fastness To Rubbing

Test Method: ISO 105 X12:2016

Test Stage: As Received Stage

Sample (A)	Result	Client Requirement
Dry Rub	4-5	3-4
Wet Rub	4	3

05. Color Fastness To Perspiration

Test Method: ISO 105 E04:2013

Test Condition: Temperature at 37±2 degrees, Time 4 hours.

Sample (A)	Result	Result	Client Requirement
	Acid	Alkaline
Color Change	4	4	4
Color staining	4	4	3-4
-Acetate	4-5	4-5
-Cotton	4-5	4-5
-Nylon	4-5	4-5
-Polyester	4-5	4-5
-Acrylic	4-5	4-5
-Wool	4-5	4-5

06. Bursting Strength

Test Method: ISO 13938-2:2019, used 50 cm2 dia

Test Stage: As Received Stage

Sample (A)	Result	Client Requirement
Average	199.9 kPa	125 kPa

07. Resistance Of Pilling (ICI Box Method)

Test Method: EN ISO 12945-1:2020

Test Condition: As Received Stage

Sample (A)	Result	Result	Client Requirement
After 10,800 Cycle	Length Direction	Width Direction
Grade	4	4	3-4
Note: Fuzzy effects are observed

 Visual Assessment 

Grade	Description
5	No Change
4	Slight Surface fuzzing and/or partially formed pills.
3	Moderate surface fuzzing and/or moderate pilling. Pills of varying sizes and densities cover the specimen surface.
2	Distinct surface fuzzing and/or distinct pilling. Pills of varying size and density cover a large proportion of the specimen surface.
1	Dense surface fuzzing and/or severe pilling. Pills of varying size and density cover the whole of the specimen surface.

08. Mass Per Unit Area

Test Method: EN 12127: 1998

Test Stage: As Received Stage

Sample (A)	Result	Client Requirement
Average	315.0 g/m2	310 g/m2(±5%)

Test Comments:

All the test result is good. We can follow the overall process to achieve buyers’ requirements.

Final word:

Yes, we are at the end of the article. The overall fleece fabric and its knitting, dyeing, finishing, and testing process and parameters are actual. Everyone can follow this process and parameter. But don’t miss following the comments.

You may read some other articles:

• Can I Put Rit Dye Directly On Fabric? Some Answers and Myths We’ve Heard
• Flow Chart Of Space Dyeing Process
• What Is Space Dye? Advantages Of Space Dye
• What is Garments Dyeing? || Advantages & Differences Between Garments And Fabrics Dyeing
• What Is The Best Fabric Dye For Polyester? 4 Superlative Dye Review: