How is Fleece Made?

By LogoSportswear

Fleece is a popular fabric used in making jackets, sweaters, beanies, and blankets as they are perfect for keeping people warm, cozy, and comfortable. But have you ever been curious about how it's made? In this article, LogoSportswear explains the process of how fleece is manufactured, from raw materials to the soft and fluffy fabric that many love.

What is fleece actually made of?

Fleece is a type of fabric made from a mix of synthetic fibers and polyethylene terephthalate or PET, a type of polyester. It offers the same warmth and softness as wool but is lighter and moisture-resistant. These qualities make fleece a popular fabric option for a wide range of products, including outdoor apparel, casual clothing, blankets, ear warmers, gloves, and hats.

What are the different types of fleeces?

Fleece comes in several types. Here are some of the most common ones:

• Microfleece - Microfleece is a thinner and lighter type of fleece. It's often used in making garments designed for layering because it adds warmth minus the heavy weight.
• Polar fleece - Polar fleece is a classic type of fleece well-known for its thickness and having air pockets. These help trap and insulate heat, which contributes to the warmth the fabric provides. Polar fleece is often used in outdoor and winter apparel, blankets, and more.
• Sherpa fleece - Sherpa, or high-pile fleece, is a type of fleece known for its soft, thick, and fluffy texture. It's closest to mimicking wool and faux fur but is 100% made of synthetic fibers. Unlike polar fleece, sherpa fleece has a more textured surface, offering extra warmth and cushioning. These qualities set sherpa fleece apart and makes it a popular choice for blankets, pet beds, winter socks, and as a lining for winter jackets.

How is fleece manufactured?

So, how is fleece made and how does it start? Let's take a quick look at its step-by-step process:

Sourcing raw materials

Creating fleece begins by sourcing the raw materials needed to turn into polyester fibers. They can be made either from petroleum-based chemicals like ethylene glycol and terephthalic acid or by collecting recycled PET bottles.

Creating polyester fiber

There are two ways in making polyester fiber:

• Virgin polyester production - Ethylene glycol and terephthalic acid undergoes polymerization, a process where petroleum-based chemicals are heated to a specific temperature. Once a chemical reaction occurs, it forms a thick liquid that hardens and is spun into fibers.
• Recycled polyester (rPET) production - Bales of plastic bottles are collected, sorted, and cleaned. They are then shredded into small chips, washed again, melted, and spun into new fibers. Light-colored chips are usually bleached, while green bottles are turned into dark-colored yarn.

Spinning the yarn

After the polyester fibers are created, they are spun into yarn to prepare them for weaving or knitting. The fibers go through a spinning machine, where they are twisted together to form a single strand and collected onto large spools.

Knitting or weaving

During this process, the polyester fibers are either knitted or woven into fabric. If the fibers are woven, it creates a tighter and more durable fabric that is suitable for outdoor apparel and blankets. For knitted fibers, the fabric comes out softer and more flexible, making them perfect for comfortable clothing.

Napping and brushing the fabric

After knitting or weaving, the fabric is placed into a napper to make it extra soft. This process is done by brushing the French terry's surface with wire brushes and cutting the raised fibers through a shearing machine, giving fleece its fluffy texture.

Dyeing and finishing

For the final process, the fleece fabric is dyed to enhance its appearance. The fabric is also given various types of treatments that improve its water- and moisture-resistance, as well as treatments that prevent pilling and enhance the fabric's softness.

Fleece is a go-to fabric for outdoor and casual wear, known for its perfect blend of warmth and durability. From the creation of its raw materials to the brushing process that gives it that soft, cozy feel, fleece continues to be versatile and serves as a great alternative to other fabrics.