The delicacy possessed by Soalon,
combined with the traditional techniques inherited by Japanese craftsmen, creates various beautiful fabrics.
Making Process
Transparent and lustrous triacetate yarn produced in Toyama Prefecture is transformed into beautiful fabrics by the skills of craftsmen in Hokuriku and other textile production areas in Japan. Soalon is a fiber made mainly from natural pulp, which is extremely delicate and changes slightly depending on temperature and humidity.
Craftsmen check it with their fingers and eyes, and gradually adjust the traditional machines to transform it into beautiful fabrics.
Soalon is a product that has continued to be made by skilled craftsmen who have nurtured their skills and passed them on as a unique tradition. We would like to continue this “craftsmanship” into the future together with Japanese production areas.
The fiber are collected as they flow finely from the nozzle like a shower, and then wound together into a single strand.
Soalon triacetate fiber is made in SOALON Corporation’s Toyama Plant in Toyama City, Toyama Prefecture.Acetate flakes made from the reaction between natural pulp and acetic acid are dissolved in an organic solvent. Spinning begins from this syrupy stock liquid.The filtered stock liquid is released through a nozzle full of small holes like a shower.The dozens of threads in the shower become interlaced and then entwined under air pressure, eventually gathering into a single yarn that is wound onto a pirn.The organic solvent in which acetate flakes have been dissolved is dried while the yarn is being made. Organic solvent that evaporates during this process is collected in pipes around the plant, recycled in a separate facility, and reused as stock liquid.
Yarn wound onto the pirn is carefully inspected to make sure there is no fluff or fraying. Rejected yarn is melted and reused.The paper tube that forms the core of the pirn is reused, too.In every process, we think about the environment and how to use resources efficiently.We make dozens of types of yarn depending on their thickness, transparency, elasticity, added functionality, etc. and then pack them into cardboard boxes for shipment to weaving factories and knitting factories.
The process to bring out the various expressions of yarns
After delivery from SOALON corporation to the weaving factory, the Soalon first undergoes “twisting”.
In this process, yarns are twisted to make them stronger and to change their texture and appearance.
The smooth touch and the unique graininess seen in Chirimen are the result of the twisting process.
Soalon is an extremely delicate yarn, so it must be twisted slowly and carefully, taking great care to avoid overloading the yarn.
In addition, by twisting with other yarns, various types of yarns are produced. Skilled craftsmen can create the foundation for high-quality and diverse fabrics by making full use of the twisting know-how they have cultivated over the years.
The twisted yarn then undergoes “warping”. This is the job of arranging the required quantity, length, density, etc. of warp yarn. Next, the yarn undergoes drawing-in, which means setting it into a loom in preparation for weaving.
Controlled by computer, but workers’ skill and experience are essential
It is called “weaving” to cross the weft yarn up and down between the tens of thousands of warp yarns set on the loom.
There are various types of looms that transform a single yarn into a piece of textile.
Water jet looms use water pressure to thread weft yarns, air jet looms, which use air pressure to pass the weft yarns through the loom, rapier looms in which the weft yarn is carried by components called rapiers.
Once the greige fabric (white fabric before the dyeing process) has been woven, it is closely inspected mechanically and visually by workers for flaws or stains. Only lengths of fabric that meet a certain standard, so-called “A” lengths, are shipped.
Nowadays, looms are controlled by computers, but its programming reflects years of skill and experience of the workers.
Advanced technology for dyeing the delicate fabric Soalon
Dyeing the grey fabric delivered from the weaving factory starts with removing any starch and oil before feeding into the dyeing machine.Dyeing the delicate fabric Soalon without wrinkles is an advanced technique of the processing plant.The fabric can be dyed while maintaining a fine balance between dyeing time, speed, and so on.
Because Soalon is dyed at a high temperature, colors fully permeate its fibers.In particular, it can be dyed a deep, luxurious black.After the dyed fabric has dried, further heat is applied using a machine called a tenter to prevent post-wash shrinkage.Finally, the fabric is inspected and high quality products are shipped.