Solar - Expertise

The Origin of Solar’s Luxury Fabric

Origin of Fibre

Selecting world’s finest fibres to produce the most exclusive, exceptional fabrics.

The history of The House of Solar is interwoven with the constant search for the rare and luxurious. Solar explores breeding farms around the world each year to select the most precious fibres and produce exceptional fabrics.

Kinds of Fibre

Cotton

Cotton is a natural, soft and breathable fabric. Evidence suggests that the fabric was used for the first time in India dated as early as 3000 B.C.

Polyester

Polyester is scientifically made using a combination of an organic compound and petroleum. It is blended with fabrics like cotton in order to make stain and wrinkle resistant clothing. The biggest advantage of polyester is that it retains its shine, color and shape even after continuous washing.

Made In India

Solar’s fabric manufacturing premise is located in the hub of India’s textile industry. India has a large and diverse agricultural sector, having different varieties of natural fibres. Also, India is second largest textile fibre producer and the largest producer of cotton in the world.

From Fibre to Yarn

Transforming finest fibres into high quality yarn for weaving.

After shearing or harvesting, the fibres are transformed into high-quality yarn for weaving with the help of various treatment steps. The artisan breeders take care of initial cleaning and sorting after which the best weavers and leading experts handle the next stages in the production process.

STAGE 1

Sorting the Cotton fibre

Artisans manually separate fibres into a number of qualities, and sort each fibre depending on its fineness.

STAGE 2

Cleaning the Cotton fibre

Impurities like grease, straw and dirt are removed by washing the fleece.

STAGE 3 - Short Fibres

Carding the fibre

In this stage, blends of fibres are made by separating the wool fibres, disentangling and airing them to give a carding strand.

Origin

The word ‘carding’ is derived from the term ‘carduus’, which is the Latin name for thistle – a prickly plant that grows at the roadside. It is quite common for the flock to brush against thistles as they roam. This results in leaving a few tufts of wool attached.

Stage 3 - Long Fibres

Carding the fibre

The short fibres are removed after the long fibres are combed to align the fibres in parallel.

STAGE 4

The « Top »

In this stage, the < > - a continuous strand of clean fibres is obtained.

STAGE 4

Dyeing the « Top »

Before spinning, the strands are dyed in bulk.

There are different kinds of dyeing:

Top dyeing: Fibres strands are dyed prior to weaving.
Yarn dyeing: Spools of raw wool thread are dyed after spinning.
Piece dyeing: The least expensive technique wherein the product is dyed in an autoclave after weaving in its natural color.

STAGE 5

Spinning the fibre

A more durable, continuous yarn is obtained by twisting the fibres. In this stage, fibres are transformed into a smooth, fine, compact yarn.

From Yarn to Fabric

Solar’s Manufacturing Premises

We develop fabrics which are the perfect combination of innovative techniques and traditional methods. This helps us provide a soft finish and a flawless drape.

1. Bringing a collection to life

We create world-class fabrics in each collection. The House of Solar designs new, innovative fabrics on a regular basis.

2. Warping

This process involves the unwinding of yarn cones onto a warp beam ready for weaving. Then, the warp cones are wound in parallel at an even tension and specific order in a process called as drawing-in.

Only Three out of more than hundred types of weave are widely used.

Plain weave

In this process, a simple criss-cross weave is formed by simply aligning the warp and weft. Every weft thread crosses a warp thread by passing over it, then under the next one, and so on in a regular manner.

Serge weave

The weft thread is passed under two warp threads and then over two more to create a serge weave. The fabric is given a diagonal effect by offsetting one thread for each pick.

Satin weave

The satin weave is characterized by four or more weft threads floating over or under the warp thread.

3. Darning

A powerful magnifying device is used by darners in order to examine the fabric. This helps in repairing all fabrics by hand with the help of a needle.

4. Burling

A perfectly smooth surface for finishing is provided by removing all the knots. This process is performed at the same time as darning.

5. Finishing

The raw fabric that comes off is transformed into finished fabric fit to make clothing with the help of more than 50 finishing techniques like high pressure washing, stabilization treatments, steaming and singeing.

This is the place where the world’s rarest fabrics are turned into the world’s finest garments.