How a Pestemal Is Made: From Yarn to Finished Towel
A pestemal is made in eight steps: yarn selection and dyeing, warping, weaving on a shuttle, dobby or jacquard loom, cutting, fringe knotting or hemming, washing and finishing, quality control, and labelling and packing. Each step affects the towel's feel, weight, size and durability.
A pestemal goes from yarn to finished towel in eight steps: yarn, warping, weaving, cutting, edge finishing, washing, quality control and packing. Weaving decides the pattern and weight; finishing decides the feel and the look of the edges.
Key fact: Weaving decides a pestemal's pattern and weight; finishing decides its feel and edges.
Pestemal.com is a Denizli, Türkiye based pestemal manufacturer. Here is how we make pestemals.
How are Turkish towels made, step by step?
| Step | What happens | What it affects |
|---|---|---|
| 1. Yarn | Cotton, organic or recycled yarn chosen; coloured yarns dyed | Softness, colour, certifications |
| 2. Warping | Lengthwise yarns wound onto the warp beam in the stripe order | Pattern, width |
| 3. Weaving | Weft yarns woven through the warp on the loom | Weave type, GSM |
| 4. Cutting | Fabric cut into individual towels | Size |
| 5. Edges | Fringe hand-knotted or edges hemmed | Look, durability |
| 6. Washing and finishing | Fabric washed and softened | Feel, shrinkage |
| 7. Quality control | Checked for size, weight and defects | Consistency |
| 8. Labelling and packing | Labels, tags and packaging added | Branding |
What yarn is used for pestemals?
Most pestemals use cotton yarn. Organic cotton (GOTS) and recycled cotton (GRS) are popular for sustainable ranges. Stripes and colours are usually created with yarn dyed before weaving, so the colour runs through the fabric. See pestemal fabrics and yarn count and ply.
How is a pestemal woven?
The warp – the lengthwise yarns – is set on the loom in the stripe order. The loom then passes weft yarns across, over and under the warp. Shuttle looms produce classic flat weaves; dobby looms produce small geometric patterns like diamond and honeycomb; jacquard looms weave complex patterns and logos. See pestemal weave types.
How is the fringe made?
After cutting, the loose warp ends at each end of the towel are twisted and knotted into fringe, often by hand. Alternatively, the ends can be hemmed for a cleaner look, which suits hotels and commercial laundry. See fringes, tassels and hems.
Why are pestemals washed before sale?
Washing removes residues from weaving, pre-shrinks the fabric and softens the cotton. Even so, cotton pestemals keep getting softer and more absorbent in their first home washes. See why pestemals get softer.
How long does it take to make a pestemal order?
It depends on whether yarn must be dyed, the weave, branding and quantity. See production lead times.
Key takeaways
- Yarn is prepared and dyed.
- The warp is set on the loom and the fabric woven.
- Towels are cut and edges knotted or hemmed.
- Washing softens and pre-shrinks the fabric.
- Pestemal.com runs all steps in-house in Denizli.
In Denizli we run shuttle, dobby and jacquard looms and do our own cutting and sewing in-house. That keeps weaving, edge finishing, labelling and packing under one roof and one quality system.
Frequently asked questions
How are Turkish towels made?
Yarn is prepared and dyed, warped onto the loom, woven, cut into towels, finished with fringe or hems, washed, inspected and packed.
What looms are used for pestemals?
Shuttle looms for flat weaves, dobby looms for small patterns such as diamond, and jacquard looms for complex patterns and logos.
Is the fringe on a pestemal hand-knotted?
Often, yes. The loose warp ends are twisted and knotted into fringe after cutting.
Why are pestemal stripes woven rather than printed?
Woven stripes use yarn dyed before weaving, so the colour runs through the fabric and lasts longer.
Are pestemals pre-washed?
Usually yes, to remove residues, pre-shrink and soften the fabric.