When the long staple Egyptian Giza cotton from the selected farmer is arriving at the manufacturing plant, the Giza cotton fibers need to undergo a process to turn fiber into yarn. This process is very important in the production of a our towels as the yarn characteristics are of great influence on the end result of the towel. The process includes fiber combing, spinning and twisting. We carefully selected the optimal requirements for this process to construct the perfect yarn for our towels
In weaving process three types of “threads” are combined. The ground warp thread, the pile warp thread and the weft thread. The ground warp forms is the most rigid body of the towel while the pile warp thread produces the soft towel height, the loops. The weft thread could be referred to as the crosswise thread and is the filling between the warps. The warp threads run through a set of metal eyes and are secured to harnesses. These harnesses are independent frames who are able to mechanically move up and down. In this way the weft threads (filling) can be passed between the warps threads which results in a woven Gizah towel
Bleaching and dying
After the weaving process a long roll of the towel fabric is put into a bath with bleaching fluids in order to dye it in pure white and to remove any pectin or cotton seeds. Next, the roll is washed to remove all fluid, after drying the roll is dyed in a bath in one of our disctinctive Gizah colours. In this process we strive for the highest quality of colour fastness, ensuring a high resistance to fading. In this way our towels will remain in an excellent condition after years of usage
Cutting and finishing
The rolls of towel fabric are cut into the Gizah towel formats by specialized cutting machines. First cut in longitudinal direction and afterwards in crosswise direction. When the towel fabric is cut in the right dimensions the edges need to be secured. At Gizah this is done by the process of serging, the edge is stitched creating a casing over the raw edge making it unable for the towel to unravel and maintain its quality.
The last phase in the Gizah towel production process includes the embroidery of the Gizah logo and the unique blueprint code. Every towel will get an unique embroidered code of four symbols. This process is not automated but is handcraft work which makes the towel even more exclusive. Please refer to the blueprint section to fill in your unique code.
Before shipping our towels, each towel is hand inspected by our quality employees. This is done to maintain the excellent quality that we strive for in our luxurious towels. When a fabrication error is detected the towel will be taken apart and recycled to maintain our sustainable operations.