The journey begins with the selection of fibers. Natural textile fibers, ranging from silks to soft wools and fine cashmeres, from cottons to linen, are obtained with care and dedication. Synthetic fibers, on the other hand, come to life through sophisticated technological processes.

These two souls – natural and synthetic fibers – from different worlds, constitute the starting point of the final product.

From fabric to product: where creativity takes shape

Finally, the finishing: the moment when the fabric, after being dyed and refined, is transformed into a garment, a shirt, a jacket, or any other piece of clothing.

But the expressive power of fabric is not limited to clothing. It also finds application in home decor and fashion accessories. Every product, whether worn or used to enhance an environment, becomes a tool to communicate the unique style and personality of the person who chooses it, thus completing the fabric’s journey from creation to final use.

How a Raphael fabric is made

In the intricate process leading to the creation of a fabric, Raphael focuses its expertise on weaving.

With mastery gained over more than fifty years of activity, the company manages the entire chain of operations that characterize this essential phase.

It is here that the yarns come together, giving birth to quality fabrics that embody the elegance and craftsmanship typical of Made in Italy.

Yarn Dyeing

Yarn dyeing allows the desired color to be achieved and amplifies creative potential, enabling designers to personalize fabrics with a wide range of colors and shades. This creative freedom allows them to explore infinite combinations and create unique and original fabrics.

Raphael relies on experienced suppliers, carefully selected for their professionalism. Thanks to this valuable collaboration, yarn dyeing is carried out with precision and adherence to technical specifications.

The instructions given to suppliers represent the precise interpretation of the designers’ visions and requests, thus transforming their ideas into exclusive, high-quality fabrics.

Constant supervision by Raphael also ensures compliance with eco-toxicological criteria and guarantees sustainable production that protects the environment and human health.

Warping

Warping represents the initial phase of the weaving process, where the threads are arranged precisely and organized according to a predetermined pattern.

The warp constitutes the supporting structure of the fabric, providing the necessary foundation for weaving.

During this phase, the threads are arranged in parallel, creating a solid and regular base on which the weft threads will be interwoven during the weaving process.

Beaming

Beaming is an essential phase in the weaving process, during which the warp threads are carefully inserted into the heddles and reed of the loom. This step prepares the loom for the next phase of weaving, ensuring a precise and stable organization of the threads.

There are different beaming techniques. At Raphael, we adopt the so-called mask beaming, which involves using a single thread that passes through a system of slats, heddles, and reeds. This innovative approach standardizes the process, reduces preparation time and costs, offering greater flexibility.

Knotting

Knotting is a craft operation within the industrial weaving process: the threads of a new warp are connected to those of the previous one.

This step requires manual skill and precision to ensure a smooth and continuous transition in production. The experience and craftsmanship of the operators involved allow them to create solid and invisible joins, ensuring that the final fabric maintains a cohesive and uniform structure.

Shuttle Weaving

This constitutes the heart of the weaving phase: the weft and warp threads interlace to create the fabric’s weave, defining its pattern, strength, and aesthetic characteristics. At Raphael, shuttle weaving is carried out both on shuttle looms and Jacquard looms, offering a wide range of technical and creative possibilities.
Shuttle looms, thanks to their versatility, allow for working with various fabric weights, from ultra-light to the heaviest, ensuring precision and quality in every fabric unit (piece).

Jacquard looms, on the other hand, allow for the creation of intricate designs and patterns, adding a touch of originality and customization to our fabrics. The possibility of combining yarn dyeing with Jacquard weaving gives designers maximum creative freedom to craft unique and distinctive fabrics. The integration of color choices and complex patterns enables the creation of extraordinary textile works.

Spooling

Spooling is a complementary process in the weaving process, which involves carefully winding the weft or warp threads onto a spool. This procedure allows for more organized and efficient work, optimizing production times and facilitating the operator’s work on the production machines.

Quality Control

Quality control is an intermediate step between weaving and the subsequent processes of dyeing and finishing. A specialized operator performs a thorough visual and tactile inspection, identifying any knots, defects, or imperfections.

Through a sensitive exploration of the fabric, the operator checks its consistency, structure, and integrity. If any anomalies are found, the operator intervenes with repairs or carefully untangles knots. The goal is to ensure that every fabric batch is suitable: a defect-free fabric is the key to the value of the finished product.

Dyeing and Finishing

The dyeing and finishing phase represents an essential process to give the fabric its desired appearance and distinctive characteristics.

At Raphael, we collaborate with specialized suppliers who share our passion for textile excellence. Thanks to this partnership, we ensure that the final result faithfully matches the provided sample, maintaining the required consistency and quality.

During dyeing and finishing, numerous treatments are applied to enhance both the aesthetic and functional properties of the fabric. One of the key aspects is the evaluation of the “hand,” a term that describes the tactile sensation of the fabric, including softness, smoothness, and fullness. The evaluation of the hand is performed by experts whose sensitivity helps define the fabric’s qualities.

At Raphael, we offer a wide range of finishes, from traditional treatments to innovative solutions. Among these, we have pile formation, which adds texture and volume to the fabric; paper hand, which provides a light and thin sensation; singeing, which gives a matte and faded look; coating, which creates a protective or decorative layer on the surface; and ready-for-printing, which prepares the fabric for the application of custom designs and decorations.

Finished Product Control

The final phase of the weaving process is dedicated to a thorough inspection of the finished product.
At Raphael, each meter of fabric undergoes meticulous evaluation to ensure it meets high-quality standards.

Our experts carefully examine the piece to ensure it is free from defects or imperfections. The final inspection guarantees that each batch, ready for the market, is flawless and suitable for high-fashion creations.