Complete Explanation of the Production Process of Printed Jersey Fabric

A Complete Guide to the Printed Jersey Fabric Production Process: From Yarn to Finished Product – Intricate Craftsmanship

Printed jersey fabric, with its softness, breathability, elasticity, and diverse patterns, is widely used in T-shirts, sportswear, and loungewear.

In the eyes of consumers, a high-quality printed jersey fabric not only boasts vibrant colors and a smooth feel but also reflects a brand's quality and technological strength.

This article will take you through the complete production process of printed jersey fabric, from raw material selection to printing and finishing, comprehensively analyzing each key step.

I. Introduction to Printed Jersey Fabric

Jersey (Single Jersey) is a single-knit fabric, lightweight, elastic, and highly breathable.

When its surface is printed, it becomes the printed jersey fabric we commonly see.

It not only offers a comfortable wearing experience but also boasts rich visual appeal due to the diversity of printing processes (such as reactive printing, digital printing, and heat transfer printing).

II. Main Production Process of Printed Jersey Fabric

The production process of printed jersey fabric can be divided into six main stages: yarn selection → weaving → pretreatment → printing → setting → finishing.

Each step plays a decisive role in the quality of the finished product.

1. Raw Material Yarn Selection

Yarn selection is the starting point of the entire production process.

Common raw materials for printed jersey fabric include:

Pure cotton yarn: moisture-wicking and breathable, soft to the touch;

Polyester-cotton blended yarn: crisp and wrinkle-resistant;

Cotton-spandex yarn: high elasticity, not easily deformed;

Bamboo fiber or modal yarn: environmentally friendly and healthy, smooth to the touch.

Yarn quality directly affects the smoothness of the fabric surface and the clarity of the print. High-quality yarn can effectively reduce problems such as yarn breakage and unevenness, ensuring stable print performance.

2. Weaving Process

Printed jersey fabric is generally woven using a circular knitting machine.

Machine needle count, density, tension, and other parameters must be strictly controlled to ensure a smooth fabric surface and uniform density.

After weaving, the greige fabric must be inspected to remove defects (such as broken threads, oil stains, holes, etc.) before proceeding to the next step.

3. Pre-treatment Process

The greige fabric must undergo pre-treatment before printing to remove impurities and grease from the fiber surface, ensuring uniform dye application.

The main steps include:

Desizing: Removing the sizing used during weaving;

Boiling: Removing natural impurities and improving hydrophilicity;

Bleaching: Improving the whiteness and cleanliness of the fabric surface;

Mercerization (optional): Enhancing luster, increasing strength and dye absorption.

The quality of pre-treatment directly affects the vibrancy and adhesion of the print.

4. Printing Process

This is the core of the entire production process.

Depending on the product positioning and pattern effect, the following processes are commonly used for printed jersey fabric:

(1) Rotary Screen Printing

Dye is transferred to the fabric surface using a nickel-plated rotary screen printing machine, suitable for mass production. Features: Rich colors, strong penetration, and low cost.

(2) Flatbed Printing

Fine patterns, strong sense of layering, suitable for mid-to-high-end products.

Features: Clear patterns, precise positioning, but slower production speed.

(3) Heat Transfer Printing

The pattern is first printed on transfer paper, then transferred to the fabric surface through high temperature.

Features: Vibrant colors, suitable for small-batch customization, pollution-free.

(4) Digital Printing

The pattern is printed directly onto the fabric surface using inkjet technology.

Features: No plate making required, high color fidelity, suitable for personalized orders.

Different printing processes require different dye systems, such as reactive dyes, disperse dyes, and pigment pastes.

5. Drying and Setting

After printing, drying and setting are required:

Drying: Evaporating moisture using a hot air oven;

Setting: Stretching at high temperature to ensure the fabric width, weight, and elasticity meet standards.

The setting temperature is generally controlled between 160℃ and 180℃, which both fixes the pattern and prevents shrinkage and deformation.

6. Finishing Processes

Finishing is a crucial step in improving the fabric's feel and functionality. Common processes include:

Softening treatment: Makes the fabric smoother and more skin-friendly;

Anti-shrinkage treatment: Improves dimensional stability;

Anti-pilling treatment: Enhances abrasion resistance;

Antibacterial and odor-resistant treatment: Suitable for sports jersey fabrics.

Through scientific finishing, printed jersey fabrics are not only more aesthetically pleasing but also meet multiple needs such as comfort and practicality.

III. Key Quality Control Points in Printed Jersey Fabric Production

**Printing Positioning Accuracy:** Prevent misalignment and ghosting;

**Color Fastness Testing:** Includes washing, rubbing, perspiration, and light fastness;

**Shrinkage Control:** Ensure dimensional stability through setting and anti-shrinkage treatment;

**Fabric Surface Smoothness:** Avoid issues such as curling, creases, and color difference;

**Environmental Testing:** Complies with OEKO-TEX and GB/T standards to ensure no harmful substance residues.

IV. Finished Characteristics of Printed Jersey Fabric

Printed jersey fabric after a complete production process typically possesses the following characteristics:

Vibrant colors and clear patterns;

Soft hand feel, breathable and comfortable;

Good elasticity and resistance to deformation;

High washing fastness and resistance to fading;

Suitable for various applications such as T-shirts, sportswear, loungewear, and children's clothing.

V. Future Development Trends

As consumers increasingly demand comfort and environmental performance, the production of printed jersey fabrics is moving towards green, energy-efficient, and personalized manufacturing:

Digital printing will gradually replace traditional processes;

Waterless dyeing technology reduces pollution;

Functional finishing gives fabrics antibacterial, quick-drying, and UV-protective properties;

The application of sustainable yarns (such as recycled cotton, modal, and bamboo fiber) is becoming a trend.

VI. Conclusion

The production of printed jersey fabrics is a comprehensive technology that integrates textile craftsmanship and design art.

Every step from yarn to finished product affects the final quality and visual effect.

Mastering standardized production processes and quality control can not only enhance product competitiveness but also create high-quality printed fabrics that meet market demands.