How Terry Knitted Fabric Circular Knitting Machines Shape the Future of Textile Manufacturing

Knitting is one of the oldest and most versatile techniques in the textile industry, transforming yarns into flexible, comfortable fabrics through the interlooping of threads. The structure of knitted fabrics—unlike woven materials that use interlacing warp and weft yarns—consists of interconnected loops that create elasticity, breathability, and softness.

Within the world of knitted fabrics, terry knitted fabric stands out as a unique category prized for its absorbency, plush texture, and durability. This fabric is widely recognized for its soft loops that create a luxurious and comfortable surface, making it a staple for towels, bathrobes, sportswear, and home textiles. The development of terry knitted fabric circular knitting machines has revolutionized the production process, combining precision engineering with high productivity to meet the growing global demand for quality terry textiles.

Terry knitted fabric is distinguished by its characteristic looped pile surface, which can appear on one or both sides of the fabric. These loops are formed during the knitting process by pulling yarn through the base structure to create small protruding loops. The result is a fabric with a soft hand feel and high moisture absorbency. Depending on the finishing process, the loops can be left uncut, producing looped terry, or cut to form velour terry, which offers a smooth, velvety surface.

Terry fabrics can be made from a range of fibers, though cotton remains the most common choice due to its natural softness, moisture absorption, and breathability. Other materials such as bamboo, hemp, modal, Tencel, and blended synthetic fibers are increasingly used to enhance specific fabric properties, such as strength, elasticity, or environmental sustainability.

Cotton Terry: Offers excellent absorbency and softness; ideal for towels and bathrobes.

Bamboo Terry: Naturally antibacterial and eco-friendly; provides silky smoothness.

Hemp Terry: Durable and strong, often used in sustainable textiles.

Modal and Tencel Terry: Enhances luster and smoothness, suitable for luxury garments.

Blended Terry Fabrics: Combine fibers to achieve specific characteristics like quick drying, elasticity, or cost efficiency.

Each fiber type influences the fabric’s final appearance, texture, and performance, allowing manufacturers to tailor terry fabrics for different markets and applications.

Terry knitted fabrics are celebrated for a wide array of physical and functional advantages, making them a preferred choice across numerous sectors:

The hallmark of terry fabric lies in its looped construction, which significantly increases surface area and capillary action. The loops efficiently trap and hold moisture, enabling the fabric to absorb several times its own weight in water. This property makes it ideal for bath and sports textiles.

The looped pile structure provides a plush and cushioned feel, ensuring comfort against the skin. Whether it’s a luxurious towel, a bathrobe, or a baby garment, terry fabric offers unmatched softness and a feeling of indulgence.

The loops also act as miniature air pockets, enhancing the fabric’s thermal insulation. This quality makes terry materials suitable not only for bath products but also for warm clothing and blankets.

Properly constructed terry fabrics are robust and long-lasting. The tightly interlocked loops resist abrasion, stretching, and tearing, even after repeated washing cycles.

Through adjustments in knitting density, loop height, and yarn composition, manufacturers can produce terry fabrics in different weights and textures—from lightweight sports fabrics to heavy, luxurious bathrobes.

With growing awareness of environmental impact, modern terry fabrics often incorporate organic cotton, bamboo, or recycled fibers. This eco-conscious approach appeals to sustainability-driven consumers worldwide.

The production of terry knitted fabric is a precise process that combines advanced machinery, high-quality raw materials, and skilled operation. Modern circular knitting machines are the backbone of this process, capable of producing large quantities of fabric with consistent quality.

The process begins with selecting suitable yarns—commonly cotton or a blend of fibers—based on the desired final fabric properties. The yarn is fed into the circular knitting machine, where multiple feeders work simultaneously to create uniform loops. The tension, speed, and density are carefully controlled to ensure even loop formation.

Circular knitting machines for terry fabrics are designed with special sinkers and needles that form loops on one or both sides of the fabric. These loops create the distinctive pile surface. Adjustments in the sinker and needle settings determine loop height, pile density, and whether the loops remain uncut or are later trimmed to form a velvety finish.

Once the knitting is complete, the fabric undergoes several finishing processes:

Scouring and Dyeing: Removes impurities and imparts desired colors.

Brushing and Shearing: For cut terry fabrics, the loops are sheared to create an even, velour-like surface.

Softening and Drying: Enhances touch, drape, and absorbency.

Stentering: Stabilizes the fabric and sets its final dimensions.

Finishing not only improves the fabric’s appearance but also influences its softness, strength, and performance in end-use applications.

Quality assurance is a vital stage in terry fabric manufacturing. Parameters such as loop density, yarn tension, color consistency, and dimensional stability are monitored using advanced sensors and inspection systems. Automated circular knitting machines equipped with digital controls minimize human error and ensure each batch meets strict industry standards.

The advancement of computerized circular knitting machines has significantly transformed terry fabric production. These machines offer remarkable speed, precision, and flexibility, enabling manufacturers to produce a wide range of terry fabrics efficiently.

Key technological improvements include:

Electronic Needle Selection: Allows intricate pattern designs and selective loop formation.

Automatic Yarn Tension Control: Ensures uniform texture and reduces material waste.

Programmable Loop Height Adjustments: Enables customization of pile height for different fabric styles.

High-Speed Production: Modern machines can achieve thousands of revolutions per minute while maintaining consistent quality.

Eco-Efficiency: Newer models consume less energy and reduce yarn waste, supporting sustainable manufacturing practices.

Manufacturers such as YUANDA and other advanced textile machinery brands continuously innovate to enhance production efficiency and adapt to global market demands. By integrating software-based monitoring systems, today’s machines offer predictive maintenance alerts, automatic defect detection, and real-time production data—essential for large-scale fabric operations.

The versatility of terry knitted fabrics makes them indispensable in various sectors:

The most widespread use of terry fabric is in towels, bathrobes, and washcloths. Its absorbency and softness make it perfect for drying and comfort. High-end brands prefer long-staple cotton or bamboo blends for superior softness and luxury appeal.

Lightweight terry fabrics are popular in sportswear due to their breathability and moisture-wicking properties. Sweatshirts, hoodies, and gym towels made from terry blends provide comfort and durability, even during intense physical activity.

Terry’s gentle touch makes it ideal for baby products such as bibs, towels, and bathrobes. The loops absorb moisture quickly, keeping the baby’s skin dry and comfortable.

Beyond the bathroom, terry fabrics are used in household products such as bath mats, sofa covers, and blankets. Cut terry varieties offer luxurious textures suitable for decorative and functional use.

In hospitals, hotels, and spas, terry fabrics are valued for hygiene, absorbency, and ease of maintenance. White terry towels and robes are standard in professional settings where comfort and cleanliness are priorities.

Certain terry fabrics are used for cleaning and polishing in automotive and industrial environments. Their absorbent and lint-free properties make them ideal for surface finishing and detailing.

Circular knitting machines offer several distinct advantages in producing terry fabrics compared to flat knitting or weaving methods:

High Productivity: Continuous circular motion allows for faster output.

Consistent Quality: Automated tension and feeding systems maintain uniform loop formation.

Versatile Design Capabilities: Easy adjustment for different pile heights, weights, and textures.

Reduced Waste: Digital precision minimizes material loss.

Energy Efficiency: Modern models feature optimized power consumption.

Scalability: Ideal for both small-batch specialty fabrics and large-scale industrial production.

These advantages have made circular knitting machines the preferred choice for manufacturers aiming to balance efficiency, cost, and quality in terry fabric production.

The global textile industry is continuously evolving, and terry fabric manufacturing is no exception. Several key trends are shaping the future of terry fabric production:

With increasing environmental awareness, more manufacturers are adopting organic cotton, recycled polyester, and bamboo yarns to reduce environmental impact.

The integration of IoT-enabled sensors and AI-driven control systems allows real-time monitoring of knitting operations, predictive maintenance, and improved resource efficiency.

Advanced programming in circular knitting machines enables rapid design changes, helping manufacturers respond to fast-changing fashion and home textile trends.

Energy-saving drives and optimized motor systems help reduce production costs while supporting sustainable manufacturing practices.

Modern terry fabrics are treated with antimicrobial, quick-drying, or stain-resistant finishes to enhance their functionality and appeal to niche markets such as sportswear and hospitality.

The demand for terry knitted fabrics continues to rise worldwide, driven by growth in home textiles, wellness, and fashion sectors. Emerging markets in Asia, particularly China, India, and Vietnam, are expanding production capacities due to strong domestic consumption and export opportunities.

China, in particular, leads in terry fabric circular knitting machine production, offering cost-effective, high-quality machines that compete internationally. With advancements in automation and material science, Chinese manufacturers have become major players in the global textile machinery market, supplying reliable equipment for both small factories and large-scale textile mills.

Terry knitted fabric represents a perfect combination of comfort, performance, and versatility—qualities that have made it indispensable in modern life. From the luxurious softness of bath towels to the functional absorbency of sportswear, terry fabrics meet diverse consumer needs with remarkable adaptability.

The introduction of advanced circular knitting machines has revolutionized the manufacturing process, enabling high-speed production, consistent quality, and innovative design possibilities. As sustainability and efficiency become central to textile manufacturing, these machines are paving the way for the next generation of eco-friendly, high-performance fabrics.

In a rapidly evolving industry, the terry knitted fabric circular knitting machine stands as a symbol of how precision engineering and creative textile design can merge to create products that offer both comfort and practicality—continuing a long tradition of innovation in the global textile landscape.