Soalon triacetate fiber is made in Mitsubishi Chemical’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 discharged 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.

After delivery from Mitsubishi Chemical to the weaving factory, the Soalon first undergoes “twisting”, then the twisted yarn 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.There are various types of loom, and we mainly use rapier looms in which the weft yarn is carried by components called rapiers.Once the grey 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 for workers to be able to program these computers takes years of skill and experience.

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.