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By Wunderlabel on 04/25/2024

Production Woven Labels

Production Process of Woven Labels

 
The production of woven labels is essential to the apparel, textile, and home goods industries. Specialized weaving machines weave yarns (warp and weft) to reproduce the desired pattern, design or logo. This meticulous weaving technique gives the labels a unique aesthetic and quality that sets them apart from other types of labels.
Woven label manufacturers must consider many aspects, from material selection to design and production. Creating a woven label requires expertise and careful handling. Here is an insight into the various steps and techniques involved in the production of woven labels.

1. Label Material Selection

Wunderlabel uses 100% recycled polyester for its damask woven labels: This material is ideal for producing different types of woven labels due to its winning combination of durability and softness. Another advantage of polyester is that it is wrinkle resistant and retains its shape even with frequent use. This is particularly important to ensure that the important information on the clothing labels remains clearly legible. Our high-end brand labels with logo, woven labels with text and symbol, and our jacquard size labels are all OEKO-TEX® Standard 100 certified.

2. From Designing to Weaving Custom Woven Labels

After the customer uploads the label design as a raster file or a vector graphic (e.g. Adobe Illustrator vector art), we match it to the specifications of the weaving machine. Once the design has been adjusted with our digital graphic programme, the yarn for the label is carefully selected. Workers position the threads in the loom and then start the weaving process. The loom has sophisticated mechanisms that allow the threads to be woven in precise patterns to create the desired design. The result is a long piece of fabric that contains the design in multiple copies. 

2.1. Sew-on Woven Labels

If the labels are to be sewn onto the fabric, another machine cuts the fabric into long strips, which are then turned and cut again. We use a hot cutting method that seals in the edges and prevents fraying. For customized woven labels with a fold (for example a Manhattan fold), there is a special folding machine that folds the individual labels neatly at the end. 

2.2. Iron-on woven labels

However, if the labels are to be ironed on, the manufacturing process is slightly different: An adhesive layer must first be applied to the back of the labels. This is either a thermoplastic glue or a special coating material. Once the adhesive layer is dry, a laser machine is used to precisely cut the individual labels out of the large piece of fabric. 

3. Final Step of the Manufacturing Process: Quality Control

Before shipping, the labels undergo strict manual quality control. The design, surface finish, cut and fold on each individual label are checked. Faulty labels are discarded and any issues reported to be addressed as soon as possible. This ensures the high standard of the labels. 
 Any discrepancies or defects are immediately addressed and corrected before the labels are packaged and shipped out to customers. Our team of skilled quality control inspectors meticulously inspect each label to ensure that they meet our standards of excellence. This dedication to quality control is just one of the many ways that we strive to provide our customers with the best possible products.  

4. Cost Considerations when Ordering Woven Labels

When considering cost, several factors come into play. The choice of material can have a significant impact on cost. The complexity of the design also plays a role: An intricately designed logo or artwork may require more time and resources to produce. Many different colors can require special weaving techniques, which also affect the price. The quantity and size of the order is important - larger order quantities can result in lower unit costs because the fixed costs can be spread over a larger number of labels. Quality standards and certification also affect the final price.


 5. High-quality Packaging and Safe Shipping

Once production is complete, the labels are carefully bundled together and packed to ensure they reached the customer in top condition. At Wunderlabel we try and avoid the use of unnecessary plastic wrapping and we use sturdy recycled cardboard packaging and paper envelopes for shipping. 

Concluding Insight into the Production Process of Woven Labels

The production of woven labels has evolved historical from hand-operated shuttle looms to automated high-speed weaving machines. This has resulted in increased speed and efficiency, as well as finer but more durable custom woven labels, while lowering costs for manufacturers and consumers. Printed labels made from satin and similar materials have also evolved and are highly sought after for their versatility, but high-quality woven clothing labels still remain the gold standard, especially for high-end designers who want their garment tags and labels to match the exquisite workmanship of their creations and their unique brand identity.
While we strive for speed, efficiency and quality in the manufacture of our products, we also place immense value on environmentally friendly and sustainable production processes for the sake of our planet and so that our customer may order woven labels with peace of mind.