English
Modal fabric is a type of textile made from the cellulose fibers of beech trees. It falls under the category of rayon, which is a regenerated cellulose fiber. Modal is known for its softness, smoothness, and ability to drape well, making it a popular choice for various apparel and textile applications. Here's an overview of how modal fabric is produced:
Production Process:
Harvesting Beech Trees:
Modal is derived from beech tree wood, primarily sourced from sustainably managed forests. The beech trees used for modal production are often fast-growing and require minimal water and pesticides.
Wood Chip Pulping:
The harvested wood undergoes a pulping process, during which it is chipped into small pieces. The wood chips are then processed to separate the cellulose from the lignin and other components.
Chemical Treatment - Alkali and Carbon Disulfide:
The separated cellulose is treated with a combination of alkali and carbon disulfide to form a viscous solution. This solution is then aged to break down the cellulose into a pulp.
Xanthation:
The pulp is then xanthated, a process that involves reacting it with carbon disulfide to create a yellowish-orange substance known as sodium cellulose xanthate.
Aging and Dissolving:
The xanthated pulp is left to age, allowing it to further break down. After aging, the pulp is dissolved in a caustic soda solution to create a viscose solution.
Extrusion and Spinning:
The viscose solution is extruded through spinnerets, forming filaments. These filaments are then immersed in a bath containing sulfuric acid, causing the cellulose to regenerate and solidify into fibers.
Washing and Neutralization:
The newly formed modal fibers go through a series of washing steps to remove impurities and chemicals. Neutralization follows, involving a bath in diluted sulfuric acid to neutralize any remaining alkali.
Drawing and Drying:
The fibers are drawn to align their molecular structure, improving their strength and elasticity. After drawing, the fibers are dried to remove excess moisture.
Cutting and Baling:
The dried fibers are cut into the desired staple length for spinning into yarns. The modal yarns are then baled and prepared for further processing.
Weaving or Knitting:
Modal yarns are woven into fabric on looms or knitted to create knit fabrics. The weaving or knitting process determines the specific texture and structure of the final fabric.
Finishing Processes:
The modal fabric may undergo various finishing processes, such as dyeing, printing, or applying finishes to enhance specific characteristics like wrinkle resistance or moisture-wicking properties.
Key Characteristics of Modal Fabric:
Softness: Modal is renowned for its luxurious softness, often compared to silk.
Breathability: Modal has excellent breathability, making it comfortable to wear in various climates.
Drapability: Modal fabric drapes well, creating flowing and flattering silhouettes.
Color Retention: Modal has good color retention, allowing for vibrant and lasting dyeing.
Moisture Absorption: Modal can absorb and release moisture efficiently, contributing to its comfort.
Environmental Considerations: Modal is often considered more environmentally friendly than conventional rayon due to its beech tree sourcing and closed-loop production processes.
Modal fabric is commonly used in the production of garments such as underwear, loungewear, activewear, and various types of clothing where a soft and comfortable feel is desired.
